Expansion cone for radially expanding tubular members

ABSTRACT

An expansion cone for radially expanding tubular members.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a division of U.S. patent application Ser.No. 09/588,946, attorney docket number 25791.17.02, which was acontinuation-in-part of U.S. patent application Ser. No. 09/559,122,attorney docket number 25791.23.02, which claimed the benefit of thefiling date of U.S. provisional patent application serial No.60/131,106, filed on Apr. 26, 1999, which was a continuation-in-part ofU.S. patent application Ser. No. 09/523,460, attorney docket number25791.11.02, which claimed the benefit of the filing date of U.S.provisional patent application serial No. 60/124,042, filed on Mar. 11,1999, which was a continuation-in-part of U.S. patent application Ser.No. 09/510,913, attorney docket number 25791.7.02, which claimed thebenefit of the filing date of U.S. provisional patent application serialNo. 60/121,702, filed on Feb. 25, 1999, which was a continuation-in-partof U.S. patent application Ser. No. 09/502,350, attorney docket number25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional patent application serial No.60/119,611, attorney docket number 25791.8, filed on Feb. 11, 1999,which was a continuation-in-part of U.S. patent application Ser. No.09/454,139, attorney docket number 25791.3.02, filed on Dec. 3, 1999,which claimed the benefit of the filing date of U.S. provisional patentapplication serial No. 60/111,293, filed on Dec. 7, 1998.

[0002] This application is related to the following co-pendingapplications: provisional patent application No. 60/108,558, filed Nov.16, 1998, provisional patent application No. 60/111,293, filed Dec. 7,1998, provisional patent application No. 60/119,611, filed Feb. 11,1999, provisional patent application No. 60/121,702, filed Feb. 25,1999, provisional patent application No. 60/121,907, filed Feb. 26,1999, provisional patent application No. 60/124,042, filed Mar. 11,1999, and provisional patent application No. 60/131,106, filed Apr. 26,1999, the disclosures of which are incorporated by reference.

BACKGROUND OF THE INVENTION

[0003] This invention relates generally to wellbore casings, and inparticular to wellbore casings that are formed using expandable tubing.

[0004] Conventionally, when a wellbore is created, a number of casingsare installed in the borehole to prevent collapse of the borehole walland to prevent undesired outflow of drilling fluid into the formation orinflow of fluid from the formation into the borehole. The borehole isdrilled in intervals whereby a casing which is to be installed in alower borehole interval is lowered through a previously installed casingof an upper borehole interval. As a consequence of this procedure thecasing of the lower interval is of smaller diameter than the casing ofthe upper interval. Thus, the casings are in a nested arrangement withcasing diameters decreasing in downward direction. Cement annuli areprovided between the outer surfaces of the casings and the borehole wallto seal the casings from the borehole wall. As a consequence of thisnested arrangement a relatively large borehole diameter is required atthe upper part of the wellbore. Such a large borehole diameter involvesincreased costs due to heavy casing handling equipment, large drill bitsand increased volumes of drilling fluid and drill cuttings. Moreover,increased drilling rig time is involved due to required cement pumping,cement hardening, required equipment changes due to large variations inhole diameters drilled in the course of the well, and the large volumeof cuttings drilled and removed.

[0005] Conventionally, at the surface end of the wellbore, a wellhead isformed that typically includes a surface casing, a number of productionand/or drilling spools, valving, and a Christmas tree. Typically thewellhead further includes a concentric arrangement of casings includinga production casing and one or more intermediate casings. The casingsare typically supported using load bearing slips positioned above theground. The conventional design and construction of wellheads isexpensive and complex.

[0006] Conventionally, a wellbore casing cannot be formed during thedrilling of a wellbore. Typically, the wellbore is drilled and then awellbore casing is formed in the newly drilled section of the wellbore.This delays the completion of a well.

[0007] The present invention is directed to overcoming one or more ofthe limitations of the existing procedures for forming wellbores andwellheads.

SUMMARY OF THE INVENTION

[0008] According to one aspect of the present invention, an expansioncone for expanding a tubular member is provided that includes a housingincluding a tapered first end and a second end, one or more groovesformed in the outer surface of the tapered first end, and one or moreaxial flow passages fluidicly coupled to the circumferential grooves.

[0009] According to another aspect of the present invention, a method oflubricating the interface between a tubular member and an expansion conehaving a first tapered end and a second end during the radial expansionof the tubular member by the expansion cone, wherein the interfacebetween the tubular member and the first tapered end of the expansioncone includes a leading edge portion and a trailing edge portion, isprovided that includes injecting a lubricating fluid into the trailingedge portion.

[0010] According to another aspect of the present invention, a method ofremoving debris formed during the radial expansion of a tubular memberby an expansion cone from the interface between the tubular member andthe expansion cone, the expansion cone including a first tapered end anda second end, the interface between the tubular member and the firsttapered end of the expansion cone includes a leading edge portion and atrailing edge portion, is provided that includes injecting a lubricatingfluid into the interface between the tubular member and the expansioncone.

[0011] According to another aspect of the present invention, a tubularmember is provided that includes an annular member having a wallthickness that varies less than about 8%, a hoop yield strength thatvaries less than about 10%, imperfections of less than about 8% of thewall thickness, no failure for radial expansions of up to about 30%, andno necking of the walls of the annular member for radial expansions ofup to about 25%.

[0012] According to another aspect of the present invention, a wellborecasing is provided that includes one or more tubular members. Eachtubular member includes an annular member having a wall thickness thatvaries less than about 8%, a hoop yield strength that varies less thanabout 10%, imperfections of less than about 8% of the wall thickness, nofailure for radial expansions of up to about 30%, and no necking of thewalls of the annular member for radial expansions of up to about 25%.

[0013] According to another aspect of the present invention, a method offorming a wellbore casing is provided that includes placing a tubularmember and an expansion cone in a wellbore and displacing the expansioncone relative to the tubular member. The tubular member includes anannular member having a wall thickness that varies less than about 8%, ahoop yield strength that varies less than about 10%, imperfections ofless than about 8% of the wall thickness, no failure for radialexpansions of up to about 30%, and no necking of the walls of theannular member for radial expansions of up to about 25%.

[0014] According to another aspect of the present invention, a method ofselecting a group of tubular members for subsequent radial expansion isprovided that includes radially expanding the ends of a representativesample of the group of tubular members, measuring the amount of neckingof the walls of the radially expanded ends of the tubular members, andif the radially expanded ends of the tubular members do not exhibitnecking for radial expansions of up to about 25%, then accepting thegroup of tubular members.

[0015] According to another aspect of the present invention, a method ofselecting a group of tubular members is provided that includes radiallyexpanding the ends of a representative sample of the group of tubularmembers until each of the tubular members fail, and if the radiallyexpanded ends of the tubular members do not fail for radial expansionsof up to about 30%, then accepting the group of tubular members.

[0016] According to another aspect of the present invention, a method ofinserting a tubular member into a wellbore is provided that includesinjecting a lubricating fluid into the wellbore and inserting thetubular member into the wellbore.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017]FIG. 1 is a fragmentary cross-sectional view illustrating thedrilling of a new section of a well borehole.

[0018]FIG. 2 is a fragmentary cross-sectional view illustrating theplacement of an embodiment of an apparatus for creating a casing withinthe new section of the well borehole.

[0019]FIG. 3 is a fragmentary cross-sectional view illustrating theinjection of a first quantity of a fluidic material into the new sectionof the well borehole.

[0020]FIG. 3a is another fragmentary cross-sectional view illustratingthe injection of a first quantity of a hardenable fluidic sealingmaterial into the new section of the well borehole.

[0021]FIG. 4 is a fragmentary cross-sectional view illustrating theinjection of a second quantity of a fluidic material into the newsection of the well borehole.

[0022]FIG. 5 is a fragmentary cross-sectional view illustrating thedrilling out of a portion of the cured hardenable fluidic sealingmaterial from the new section of the well borehole.

[0023]FIG. 6 is a cross-sectional view of an embodiment of theoverlapping joint between adjacent tubular members.

[0024]FIG. 7 is a fragmentary cross-sectional view of a preferredembodiment of the apparatus for creating a casing within a wellborehole.

[0025]FIG. 8 is a fragmentary cross-sectional illustration of theplacement of an expanded tubular member within another tubular member.

[0026]FIG. 9 is a cross-sectional illustration of a preferred embodimentof an apparatus for forming a casing including a drillable mandrel andshoe.

[0027]FIG. 9a is another cross-sectional illustration of the apparatusof FIG. 9.

[0028]FIG. 9b is another cross-sectional illustration of the apparatusof FIG. 9.

[0029]FIG. 9c is another cross-sectional illustration of the apparatusof FIG. 9.

[0030]FIG. 10a is a cross-sectional illustration of a wellbore includinga pair of adjacent overlapping casings.

[0031]FIG. 10b is a cross-sectional illustration of an apparatus andmethod for creating a tie-back liner using an expandable tubular member.

[0032]FIG. 10c is a cross-sectional illustration of the pumping of afluidic sealing material into the annular region between the tubularmember and the existing casing.

[0033]FIG. 10d is a cross-sectional illustration of the pressurizing ofthe interior of the tubular member below the mandrel.

[0034]FIG. 10e is a cross-sectional illustration of the extrusion of thetubular member off of the mandrel.

[0035]FIG. 10f is a cross-sectional illustration of the tie-back linerbefore drilling out the shoe and packer.

[0036]FIG. 10g is a cross-sectional illustration of the completedtie-back liner created using an expandable tubular member.

[0037]FIG. 11a is a fragmentary cross-sectional view illustrating thedrilling of a new section of a well borehole.

[0038]FIG. 11b is a fragmentary cross-sectional view illustrating theplacement of an embodiment of an apparatus for hanging a tubular linerwithin the new section of the well borehole.

[0039]FIG. 11c is a fragmentary cross-sectional view illustrating theinjection of a first quantity of a hardenable fluidic sealing materialinto the new section of the well borehole.

[0040]FIG. 11d is a fragmentary cross-sectional view illustrating theintroduction of a wiper dart into the new section of the well borehole.

[0041]FIG. 11e is a fragmentary cross-sectional view illustrating theinjection of a second quantity of a hardenable fluidic sealing materialinto the new section of the well borehole.

[0042]FIG. 11f is a fragmentary cross-sectional view illustrating thecompletion of the tubular liner.

[0043]FIG. 12 is a cross-sectional illustration of a preferredembodiment of a wellhead system utilizing expandable tubular members.

[0044]FIG. 13 is a partial cross-sectional illustration of a preferredembodiment of the wellhead system of FIG. 12.

[0045]FIG. 14a is an illustration of the formation of an embodiment of amono-diameter wellbore casing.

[0046]FIG. 14b is another illustration of the formation of themono-diameter wellbore casing.

[0047]FIG. 14c is another illustration of the formation of themono-diameter wellbore casing.

[0048]FIG. 14d is another illustration of the formation of themono-diameter welbore casing.

[0049]FIG. 14e is another illustration of the formation of themono-diameter welbore casing.

[0050]FIG. 14f is another illustration of the formation of themono-diameter welbore casing.

[0051]FIG. 15 is an illustration of an embodiment of an apparatus forexpanding a tubular member.

[0052]FIG. 15a is another illustration of the apparatus of FIG. 15.

[0053]FIG. 15b is another illustration of the apparatus of FIG. 15.

[0054]FIG. 16 is an illustration of an embodiment of an apparatus forforming a mono-diameter wellbore casing.

[0055]FIG. 17 is an illustration of an embodiment of an apparatus forexpanding a tubular member.

[0056]FIG. 17a is another illustration of the apparatus of FIG. 16.

[0057]FIG. 17b is another illustration of the apparatus of FIG. 16.

[0058]FIG. 18 is an illustration of an embodiment of an apparatus forforming a mono-diameter wellbore casing.

[0059]FIG. 19 is an illustration of another embodiment of an apparatusfor expanding a tubular member.

[0060]FIG. 19a is another illustration of the apparatus of FIG. 17.

[0061]FIG. 19b is another illustration of the apparatus of FIG. 17.

[0062]FIG. 20 is an illustration of an embodiment of an apparatus forforming a mono-diameter wellbore casing.

[0063]FIG. 21 is an illustration of the isolation of subterranean zonesusing expandable tubulars.

[0064]FIG. 22a is a fragmentary cross-sectional illustration of anembodiment of an apparatus for forming a wellbore casing while drillinga welbore.

[0065]FIG. 22b is another fragmentary cross-sectional illustration ofthe apparatus of FIG. 22a.

[0066]FIG. 22c is another fragmentary cross-sectional illustration ofthe apparatus of FIG. 22a.

[0067]FIG. 22d is another fragmentary cross-sectional illustration ofthe apparatus of FIG. 22a.

[0068]FIG. 23a is a fragmentary cross-section illustration of anembodiment of an apparatus and method for expanding tubular members.

[0069]FIG. 23b is another fragmentary cross-sectional illustration ofthe apparatus of FIG. 23a.

[0070]FIG. 23c is another fragmentary cross-sectional illustration ofthe apparatus of FIG. 23a.

[0071]FIG. 24a is a fragmentary cross-section illustration of anembodiment of an apparatus and method for expanding tubular members.

[0072]FIG. 24b is another fragmentary cross-sectional illustration ofthe apparatus of FIG. 24a.

[0073]FIG. 24c is another fragmentary cross-sectional illustration ofthe apparatus of FIG. 24a.

[0074]FIG. 24d is another fragmentary cross-sectional illustration ofthe apparatus of FIG. 24a.

[0075]FIG. 24e is another fragmentary cross-sectional illustration ofthe apparatus of FIG. 24a.

[0076]FIG. 25 is a partial cross-sectional illustration of an expansionmandrel expanding a tubular member.

[0077]FIG. 26 is a graphical illustration of the relationship betweenpropagation pressure and the angle of attack of the expansion mandrel.

[0078]FIG. 27 is a cross-sectional illustration of an embodiment of anexpandable connector.

[0079]FIG. 28 is a cross-sectional illustration of another embodiment ofan expandable connector.

[0080]FIG. 29 is a cross-sectional illustration of another embodiment ofan expandable connector.

[0081]FIG. 30 is a cross-sectional illustration of another embodiment ofan expandable connector.

[0082]FIG. 31 is a fragmentary cross-sectional illustration of thelubrication of the interface between an expansion mandrel and a tubularmember during the radial expansion process.

[0083]FIG. 32 is an illustration of an embodiment of an expansionmandrel including a system for lubricating the interface between theexpansion mandrel and a tubular member during the radial expansion ofthe tubular member.

[0084]FIG. 33 is an illustration of an embodiment of an expansionmandrel including a system for lubricating the interface between theexpansion mandrel and a tubular member during the radial expansion ofthe tubular member.

[0085]FIG. 34 is an illustration of an embodiment of an expansionmandrel including a system for lubricating the interface between theexpansion mandrel and a tubular member during the radial expansion ofthe tubular member.

[0086]FIG. 35 is an illustration of an embodiment of an expansionmandrel including a system for lubricating the interface between theexpansion mandrel and a tubular member during the radial expansion ofthe tubular member.

[0087]FIG. 36 is an illustration of an embodiment of an expansionmandrel including a system for lubricating the interface between theexpansion mandrel and a tubular member during the radial expansion ofthe tubular member.

[0088]FIG. 37 is an illustration of an embodiment of an expansionmandrel including a system for lubricating the interface between theexpansion mandrel and a tubular member during the radial expansion ofthe tubular member.

[0089]FIG. 38 is an illustration of an embodiment of an expansionmandrel including a system for lubricating the interface between theexpansion mandrel and a tubular member during the radial expansion ofthe tubular member.

[0090]FIG. 39 is an illustration of a preferred embodiment of anexpansion mandrel including a system for lubricating the interfacebetween the expansion mandrel and a tubular member during the radialexpansion of the tubular member.

[0091]FIG. 40 is a cross-sectional illustration of the first axialgroove of the expansion mandrel of FIG. 39.

[0092]FIG. 41 is a cross-sectional illustration of the circumferentialgroove of the expansion mandrel of FIG. 39.

[0093]FIG. 42 is a cross-sectional illustration of one of the secondaxial grooves of the expansion mandrel of FIG. 39.

[0094]FIG. 43 is a cross sectional illustration of an embodiment of anexpansion mandrel including internal flow passages having inserts foradjusting the flow of lubricant fluids.

[0095]FIG. 44 is a cross sectional illustration of the expansion mandrelof FIG. 43 further including an insert having a filter for filtering outforeign materials from the lubricant fluids.

[0096]FIG. 45 is a cross sectional illustration of a preferredembodiment of an expandible tubular for use in forming and/or repairinga wellbore casing, pipeline, or foundation support.

[0097]FIG. 46 is a cross sectional illustration of the flared end of atubular member selected for testing.

[0098]FIG. 47 is a cross sectional illustration of the flared end of atubular member selected for testing that has structurally failed.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

[0099] An apparatus and method for forming a wellbore casing within asubterranean formation is provided. The apparatus and method permits awellbore casing to be formed in a subterranean formation by placing atubular member and a mandrel in a new section of a wellbore, and thenextruding the tubular member off of the mandrel by pressurizing aninterior portion of the tubular member. The apparatus and method furtherpermits adjacent tubular members in the wellbore to be joined using anoverlapping joint that prevents fluid and or gas passage. The apparatusand method further permits a new tubular member to be supported by anexisting tubular member by expanding the new tubular member intoengagement with the existing tubular member. The apparatus and methodfurther minimizes the reduction in the hole size of the wellbore casingnecessitated by the addition of new sections of wellbore casing.

[0100] An apparatus and method for forming a tie-back liner using anexpandable tubular member is also provided. The apparatus and methodpermits a tie-back liner to be created by extruding a tubular member offof a mandrel by pressurizing and interior portion of the tubular member.In this manner, a tie-back liner is produced. The apparatus and methodfurther permits adjacent tubular members in the wellbore to be joinedusing an overlapping joint that prevents fluid and/or gas passage. Theapparatus and method further permits a new tubular member to besupported by an existing tubular member by expanding the new tubularmember into engagement with the existing tubular member.

[0101] An apparatus and method for expanding a tubular member is alsoprovided that includes an expandable tubular member, mandrel and a shoe.In a preferred embodiment, the interior portions of the apparatus iscomposed of materials that permit the interior portions to be removedusing a conventional drilling apparatus. In this manner, in the event ofa malfunction in a downhole region, the apparatus may be easily removed.

[0102] An apparatus and method for hanging an expandable tubular linerin a wellbore is also provided. The apparatus and method permit atubular liner to be attached to an existing section of casing. Theapparatus and method further have application to the joining of tubularmembers in general.

[0103] An apparatus and method for forming a wellhead system is alsoprovided. The apparatus and method permit a wellhead to be formedincluding a number of expandable tubular members positioned in aconcentric arrangement. The wellhead preferably includes an outer casingthat supports a plurality of concentric casings using contact pressurebetween the inner casings and the outer casing. The resulting wellheadsystem eliminates many of the spools conventionally required, reducesthe height of the Christmas tree facilitating servicing, lowers the loadbearing areas of the wellhead resulting in a more stable system, andeliminates costly and expensive hanger systems.

[0104] An apparatus and method for forming a mono-diameter well casingis also provided. The apparatus and method permit the creation of a wellcasing in a wellbore having a substantially constant internal diameter.In this manner, the operation of an oil or gas well is greatlysimplified.

[0105] An apparatus and method for expanding tubular members is alsoprovided. The apparatus and method utilize a piston-cylinderconfiguration in which a pressurized chamber is used to drive a mandrelto radially expand tubular members. In this manner, higher operatingpressures can be utilized. Throughout the radial expansion process, thetubular member is never placed in direct contact with the operatingpressures. In this manner, damage to the tubular member is preventedwhile also permitting controlled radial expansion of the tubular memberin a wellbore.

[0106] An apparatus and method for forming a mono-diameter wellborecasing is also provided. The apparatus and method utilize apiston-cylinder configuration in which a pressurized chamber is used todrive a mandrel to radially expand tubular members. In this manner,higher operating pressures can be utilized. Throughput the radialexpansion process, the tubular member is never placed in direct contactwith the operating pressures. In this manner, damage to the tubularmember is prevented while also permitting controlled radial expansion ofthe tubular member in a wellbore.

[0107] An apparatus and method for isolating one or more subterraneanzones from one or more other subterranean zones is also provided. Theapparatus and method permits a producing zone to be isolated from anonproducing zone using a combination of solid and slotted tubulars. Inthe production mode, the teachings of the present disclosure may be usedin combination with conventional, well known, production completionequipment and methods using a series of packers, solid tubing,perforated tubing, and sliding sleeves, which will be inserted into thedisclosed apparatus to permit the commingling and/or isolation of thesubterranean zones from each other.

[0108] An apparatus and method for forming a wellbore casing while thewellbore is drilled is also provided. In this manner, a wellbore casingcan be formed simultaneous with the drilling out of a new section of thewellbore. In a preferred embodiment, the apparatus and method is used incombination with one or more of the apparatus and methods disclosed inthe present disclosure for forming wellbore casings using expandabletubulars. Alternatively, the method and apparatus can be used to createa pipeline or tunnel in a time efficient manner.

[0109] An expandable connector is also provided. In a preferredimplementation, the expandable connector is used in conjunction with oneor more of the disclosed embodiments for expanding tubular members. Inthis manner, the expansion of a plurality of tubular members coupled toone another using the expandable connector is optimized.

[0110] A lubrication and self-cleaning system for an expansion cone isalso provided. In a preferred implementation, the expansion coneincludes one or more circumferential grooves and one or more axialgrooves for providing a supply of lubricating fluid to the trailing edgeportion of the interface between the expansion cone and a tubular memberduring the radial expansion process. In this manner, the frictionalforces created during the radial expansion process are reduced whichresults in a reduction in the required operating pressures for radiallyexpanding the tubular member. Furthermore, the supply of lubricatingfluid preferably removes loose material from tapered end of theexpansion cone that is formed during the radial expansion process.

[0111] A method of testing and selecting tubular members for radialexpansion operations is also provided. In a preferred embodiment, themethod provides tubular members that are optimally suited for radialexpansion. In this manner, radially expanded tubular members havingoptimal structural properties are provided.

[0112] In several alternative embodiments, the apparatus and methods areused to form and/or repair wellbore casings, pipelines, and/orstructural supports.

[0113] Referring initially to FIGS. 1-5, an embodiment of an apparatusand method for forming a wellbore casing within a subterranean formationwill now be described. As illustrated in FIG. 1, a wellbore 100 ispositioned in a subterranean formation 105. The wellbore 100 includes anexisting cased section 110 having a tubular casing 115 and an annularouter layer of cement 120.

[0114] In order to extend the wellbore 100 into the subterraneanformation 105, a drill string 125 is used in a well known manner todrill out material from the subterranean formation 105 to form a newsection 130.

[0115] As illustrated in FIG. 2, an apparatus 200 for forming a wellborecasing in a subterranean formation is then positioned in the new section130 of the wellbore 100. The apparatus 200 preferably includes anexpandable mandrel or pig 205, a tubular member 210, a shoe 215, a lowercup seal 220, an upper cup seal 225, a fluid passage 230, a fluidpassage 235, a fluid passage 240, seals 245, and a support member 250.

[0116] The expandable mandrel 205 is coupled to and supported by thesupport member 250. The expandable mandrel 205 is preferably adapted tocontrollably expand in a radial direction. The expandable mandrel 205may comprise any number of conventional commercially availableexpandable mandrels modified in accordance with the teachings of thepresent disclosure. In a preferred embodiment, the expandable mandrel205 comprises a hydraulic expansion tool as disclosed in U.S. Pat. No.5,348,095, the contents of which are incorporated herein by reference,modified in accordance with the teachings of the present disclosure.

[0117] The tubular member 210 is supported by the expandable mandrel205. The tubular member 210 is expanded in the radial direction andextruded off of the expandable mandrel 205. The tubular member 210 maybe fabricated from any number of conventional commercially availablematerials such as, for example, Oilfield Country Tubular Goods (OCTG),13 chromium steel tubing/casing, or plastic tubing/casing. In apreferred embodiment, the tubular member 210 is fabricated from OCTG inorder to maximize strength after expansion. The inner and outerdiameters of the tubular member 210 may range, for example, fromapproximately 0.75 to 47 inches and 1.05 to 48 inches, respectively. Ina preferred embodiment, the inner and outer diameters of the tubularmember 210 range from about 3 to 15.5 inches and 3.5 to 16 inches,respectively in order to optimally provide minimal telescoping effect inthe most commonly drilled wellbore sizes. The tubular member 210preferably comprises a solid member.

[0118] In a preferred embodiment, the end portion 260 of the tubularmember 210 is slotted, perforated, or otherwise modified to catch orslow down the mandrel 205 when it completes the extrusion of tubularmember 210. In a preferred embodiment, the length of the tubular member210 is limited to minimize the possibility of buckling. For typicaltubular member 210 materials, the length of the tubular member 210 ispreferably limited to between about 40 to 20,000 feet in length.

[0119] The shoe 215 is coupled to the expandable mandrel 205 and thetubular member 210. The shoe 215 includes fluid passage 240. The shoe215 may comprise any number of conventional commercially available shoessuch as, for example, Super Seal II float shoe, Super Seal II Down-Jetfloat shoe or a guide shoe with a sealing sleeve for a latch down plugmodified in accordance with the teachings of the present disclosure. Ina preferred embodiment, the shoe 215 comprises an aluminum down-jetguide shoe with a sealing sleeve for a latch-down plug available fromHalliburton Energy Services in Dallas, Tex., modified in accordance withthe teachings of the present disclosure, in order to optimally guide thetubular member 210 in the wellbore, optimally provide an adequate sealbetween the interior and exterior diameters of the overlapping jointbetween the tubular members, and to optimally allow the complete drillout of the shoe and plug after the completion of the cementing andexpansion operations.

[0120] In a preferred embodiment, the shoe 215 includes one or morethrough and side outlet ports in fluidic communication with the fluidpassage 240. In this manner, the shoe 215 optimally injects hardenablefluidic sealing material into the region outside the shoe 215 andtubular member 210. In a preferred embodiment, the shoe 215 includes thefluid passage 240 having an inlet geometry that can receive a dartand/or a ball sealing member. In this manner, the fluid passage 240 canbe optimally sealed off by introducing a plug, dart and/or ball sealingelements into the fluid passage 230.

[0121] The lower cup seal 220 is coupled to and supported by the supportmember 250. The lower cup seal 220 prevents foreign materials fromentering the interior region of the tubular member 210 adjacent to theexpandable mandrel 205. The lower cup seal 220 may comprise any numberof conventional commercially available cup seals such as, for example,TP cups, or Selective Injection Packer (SIP) cups modified in accordancewith the teachings of the present disclosure. In a preferred embodiment,the lower cup seal 220 comprises a SIP cup seal, available fromHalliburton Energy Services in Dallas, Tex. in order to optimally blockforeign material and contain a body of lubricant.

[0122] The upper cup seal 225 is coupled to and supported by the supportmember 250. The upper cup seal 225 prevents foreign materials fromentering the interior region of the tubular member 210. The upper cupseal 225 may comprise any number of conventional commercially availablecup seals such as, for example, TP cups or SIP cups modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the upper cup seal 225 comprises a SIP cup, available fromHalliburton Energy Services in Dallas, Tex. in order to optimally blockthe entry of foreign materials and contain a body of lubricant.

[0123] The fluid passage 230 permits fluidic materials to be transportedto and from the interior region of the tubular member 210 below theexpandable mandrel 205. The fluid passage 230 is coupled to andpositioned within the support member 250 and the expandable mandrel 205.The fluid passage 230 preferably extends from a position adjacent to thesurface to the bottom of the expandable mandrel 205. The fluid passage230 is preferably positioned along a centerline of the apparatus 200.

[0124] The fluid passage 230 is preferably selected, in the casingrunning mode of operation, to transport materials such as drilling mudor formation fluids at flow rates and pressures ranging from about 0 to3,000 gallons/minute and 0 to 9,000 psi in order to minimize drag on thetubular member being run and to minimize surge pressures exerted on thewellbore which could cause a loss of wellbore fluids and lead to holecollapse.

[0125] The fluid passage 235 permits fluidic materials to be releasedfrom the fluid passage 230. In this manner, during placement of theapparatus 200 within the new section 130 of the wellbore 100, fluidicmaterials 255 forced up the fluid passage 230 can be released into thewellbore 100 above the tubular member 210 thereby minimizing surgepressures on the wellbore section 130. The fluid passage 235 is coupledto and positioned within the support member 250. The fluid passage isfurther fluidicly coupled to the fluid passage 230.

[0126] The fluid passage 235 preferably includes a control valve forcontrollably opening and closing the fluid passage 235. In a preferredembodiment, the control valve is pressure activated in order tocontrollably minimize surge pressures. The fluid passage 235 ispreferably positioned substantially orthogonal to the centerline of theapparatus 200.

[0127] The fluid passage 235 is preferably selected to convey fluidicmaterials at flow rates and pressures ranging from about 0 to 3,000gallons/minute and 0 to 9,000 psi in order to reduce the drag on theapparatus 200 during insertion into the new section 130 of the wellbore100 and to minimize surge pressures on the new wellbore section 130.

[0128] The fluid passage 240 permits fluidic materials to be transportedto and from the region exterior to the tubular member 210 and shoe 215.The fluid passage 240 is coupled to and positioned within the shoe 215in fluidic communication with the interior region of the tubular member210 below the expandable mandrel 205. The fluid passage 240 preferablyhas a cross-sectional shape that permits a plug, or other similardevice, to be placed in fluid passage 240 to thereby block furtherpassage of fluidic materials. In this manner, the interior region of thetubular member 210 below the expandable mandrel 205 can be fluidiclyisolated from the region exterior to the tubular member 210. Thispermits the interior region of the tubular member 210 below theexpandable mandrel 205 to be pressurized. The fluid passage 240 ispreferably positioned substantially along the centerline of theapparatus 200.

[0129] The fluid passage 240 is preferably selected to convey materialssuch as cement, drilling mud or epoxies at flow rates and pressuresranging from about 0 to 3,000 gallons/minute and 0 to 9,000 psi in orderto optimally fill the annular region between the tubular member 210 andthe new section 130 of the wellbore 100 with fluidic materials. In apreferred embodiment, the fluid passage 240 includes an inlet geometrythat can receive a dart and/or a ball sealing member. In this manner,the fluid passage 240 can be sealed off by introducing a plug, dartand/or ball sealing elements into the fluid passage 230.

[0130] The seals 245 are coupled to and supported by an end portion 260of the tubular member 210. The seals 245 are further positioned on anouter surface 265 of the end portion 260 of the tubular member 210. Theseals 245 permit the overlapping joint between the end portion 270 ofthe casing 115 and the portion 260 of the tubular member 210 to befluidicly sealed. The seals 245 may comprise any number of conventionalcommercially available seals such as, for example, lead, rubber, Teflon,or epoxy seals modified in accordance with the teachings of the presentdisclosure. In a preferred embodiment, the seals 245 are molded fromStratalock epoxy available from Halliburton Energy Services in Dallas,Tex. in order to optimally provide a load bearing interference fitbetween the end 260 of the tubular member 210 and the end 270 of theexisting casing 115.

[0131] In a preferred embodiment, the seals 245 are selected tooptimally provide a sufficient frictional force to support the expandedtubular member 210 from the existing casing 115. In a preferredembodiment, the frictional force optimally provided by the seals 245ranges from about 1,000 to 1,000,000 lbf in order to optimally supportthe expanded tubular member 210.

[0132] The support member 250 is coupled to the expandable mandrel 205,tubular member 210, shoe 215, and seals 220 and 225. The support member250 preferably comprises an annular member having sufficient strength tocarry the apparatus 200 into the new section 130 of the wellbore 100. Ina preferred embodiment, the support member 250 further includes one ormore conventional centralizers (not illustrated) to help stabilize theapparatus 200. In a preferred embodiment, the support member 250comprises coiled tubing.

[0133] In a preferred embodiment, a quantity of lubricant 275 isprovided in the annular region above the expandable mandrel 205 withinthe interior of the tubular member 210. In this manner, the extrusion ofthe tubular member 210 off of the expandable mandrel 205 is facilitated.The lubricant 275 may comprise any number of conventional commerciallyavailable lubricants such as, for example, Lubriplate, chlorine basedlubricants, oil based lubricants or Climax 1500 Antisieze (3100). In apreferred embodiment, the lubricant 275 comprises Climax 1500 Antisieze(3100) available from Climax Lubricants and Equipment Co. in Houston,Tex. in order to optimally provide optimum lubrication to faciliate theexpansion process.

[0134] In a preferred embodiment, the support member 250 is thoroughlycleaned prior to assembly to the remaining portions of the apparatus200. In this manner, the introduction of foreign material into theapparatus 200 is minimized. This minimizes the possibility of foreignmaterial clogging the various flow passages and valves of the apparatus200.

[0135] In a preferred embodiment, before or after positioning theapparatus 200 within the new section 130 of the wellbore 100, a coupleof wellbore volumes are circulated in order to ensure that no foreignmaterials are located within the wellbore 100 that might clog up thevarious flow passages and valves of the apparatus 200 and to ensure thatno foreign material interferes with the expansion process.

[0136] As illustrated in FIG. 3, the fluid passage 235 is then closedand a hardenable fluidic sealing material 305 is then pumped from asurface location into the fluid passage 230. The material 305 thenpasses from the fluid passage 230 into the interior region 310 of thetubular member 210 below the expandable mandrel 205. The material 305then passes from the interior region 310 into the fluid passage 240. Thematerial 305 then exits the apparatus 200 and fills the annular region315 between the exterior of the tubular member 210 and the interior wallof the new section 130 of the wellbore 100. Continued pumping of thematerial 305 causes the material 305 to fill up at least a portion ofthe annular region 315.

[0137] The material 305 is preferably pumped into the annular region 315at pressures and flow rates ranging, for example, from about 0 to 5000psi and 0 to 1,500 gallons/min, respectively. The optimum flow rate andoperating pressures vary as a function of the casing and wellbore sizes,wellbore section length, available pumping equipment, and fluidproperties of the fluidic material being pumped. The optimum flow rateand operating pressure are preferably determined using conventionalempirical methods.

[0138] The hardenable fluidic sealing material 305 may comprise anynumber of conventional commercially available hardenable fluidic sealingmaterials such as, for example, slag mix, cement or epoxy. In apreferred embodiment, the hardenable fluidic sealing material 305comprises a blended cement prepared specifically for the particular wellsection being drilled from Halliburton Energy Services in Dallas, Tex.in order to provide optimal support for tubular member 210 while alsomaintaining optimum flow characteristics so as to minimize difficultiesduring the displacement of cement in the annular region 315. The optimumblend of the blended cement is preferably determined using conventionalempirical methods.

[0139] The annular region 315 preferably is filled with the material 305in sufficient quantities to ensure that, upon radial expansion of thetubular member 210, the annular region 315 of the new section 130 of thewellbore 100 will be filled with material 305.

[0140] In a particularly preferred embodiment, as illustrated in FIG.3a, the wall thickness and/or the outer diameter of the tubular member210 is reduced in the region adjacent to the mandrel 205 in orderoptimally permit placement of the apparatus 200 in positions in thewellbore with tight clearances. Furthermore, in this manner, theinitiation of the radial expansion of the tubular member 210 during theextrusion process is optimally facilitated.

[0141] As illustrated in FIG. 4, once the annular region 315 has beenadequately filled with material 305, a plug 405, or other similardevice, is introduced into the fluid passage 240 thereby fluidiclyisolating the interior region 310 from the annular region 315. In apreferred embodiment, a non-hardenable fluidic material 306 is thenpumped into the interior region 310 causing the interior region topressurize. In this manner, the interior of the expanded tubular member210 will not contain significant amounts of cured material 305. Thisreduces and simplifies the cost of the entire process. Alternatively,the material 305 may be used during this phase of the process. Once theinterior region 310 becomes sufficiently pressurized, the tubular member210 is extruded off of the expandable mandrel 205. During the extrusionprocess, the expandable mandrel 205 may be raised out of the expandedportion of the tubular member 210. In a preferred embodiment, during theextrusion process, the mandrel 205 is raised at approximately the samerate as the tubular member 210 is expanded in order to keep the tubularmember 210 stationary relative to the new wellbore section 130. In analternative preferred embodiment, the extrusion process is commencedwith the tubular member 210 positioned above the bottom of the newwellbore section 130, keeping the mandrel 205 stationary, and allowingthe tubular member 210 to extrude off of the mandrel 205 and fall downthe new wellbore section 130 under the force of gravity.

[0142] The plug 405 is preferably placed into the fluid passage 240 byintroducing the plug 405 into the fluid passage 230 at a surfacelocation in a conventional manner. The plug 405 preferably acts tofluidicly isolate the hardenable fluidic sealing material 305 from thenon hardenable fluidic material 306.

[0143] The plug 405 may comprise any number of conventional commerciallyavailable devices from plugging a fluid passage such as, for example,Multiple Stage Cementer (MSC) latch-down plug, Omega latch-down plug orthree-wiper latch-down plug modified in accordance with the teachings ofthe present disclosure. In a preferred embodiment, the plug 405comprises a MSC latch-down plug available from Halliburton EnergyServices in Dallas, Tex.

[0144] After placement of the plug 405 in the fluid passage 240, a nonhardenable fluidic material 306 is preferably pumped into the interiorregion 310 at pressures and flow rates ranging, for example, fromapproximately 400 to 10,000 psi and 30 to 4,000 gallons/min. In thismanner, the amount of hardenable fluidic sealing material within theinterior 310 of the tubular member 210 is minimized. In a preferredembodiment, after placement of the plug 405 in the fluid passage 240,the non hardenable material 306 is preferably pumped into the interiorregion 310 at pressures and flow rates ranging from approximately 500 to9,000 psi and 40 to 3,000 gallons/min in order to maximize the extrusionspeed.

[0145] In a preferred embodiment, the apparatus 200 is adapted tominimize tensile, burst, and friction effects upon the tubular member210 during the expansion process. These effects will depend upon thegeometry of the expansion mandrel 205, the material composition of thetubular member 210 and expansion mandrel 205, the inner diameter of thetubular member 210, the wall thickness of the tubular member 210, thetype of lubricant, and the yield strength of the tubular member 210. Ingeneral, the thicker the wall thickness, the smaller the inner diameter,and the greater the yield strength of the tubular member 210, then thegreater the operating pressures required to extrude the tubular member210 off of the mandrel 205.

[0146] For typical tubular members 210, the extrusion of the tubularmember 210 off of the expandable mandrel will begin when the pressure ofthe interior region 310 reaches, for example, approximately 500 to 9,000psi.

[0147] During the extrusion process, the expandable mandrel 205 may beraised out of the expanded portion of the tubular member 210 at ratesranging, for example, from about 0 to 5 ft/sec. In a preferredembodiment, during the extrusion process, the expandable mandrel 205 israised out of the expanded portion of the tubular member 210 at ratesranging from about 0 to 2 ft/sec in order to minimize the time requiredfor the expansion process while also permitting easy control of theexpansion process.

[0148] When the end portion 260 of the tubular member 210 is extrudedoff of the expandable mandrel 205, the outer surface 265 of the endportion 260 of the tubular member 210 will preferably contact theinterior surface 410 of the end portion 270 of the casing 115 to form anfluid tight overlapping joint. The contact pressure of the overlappingjoint may range, for example, from approximately 50 to 20,000 psi. In apreferred embodiment, the contact pressure of the overlapping jointranges from approximately 400 to 10,000 psi in order to provide optimumpressure to activate the annular sealing members 245 and optimallyprovide resistance to axial motion to accommodate typical tensile andcompressive loads.

[0149] The overlapping joint between the section 410 of the existingcasing 115 and the section 265 of the expanded tubular member 210preferably provides a gaseous and fluidic seal. In a particularlypreferred embodiment, the sealing members 245 optimally provide afluidic and gaseous seal in the overlapping joint.

[0150] In a preferred embodiment, the operating pressure and flow rateof the non hardenable fluidic material 306 is controllably ramped downwhen the expandable mandrel 205 reaches the end portion 260 of thetubular member 210. In this manner, the sudden release of pressurecaused by the complete extrusion of the tubular member 210 off of theexpandable mandrel 205 can be minimized. In a preferred embodiment, theoperating pressure is reduced in a substantially linear fashion from100% to about 10% during the end of the extrusion process beginning whenthe mandrel 205 is within about 5 feet from completion of the extrusionprocess.

[0151] Alternatively, or in combination, a shock absorber is provided inthe support member 250 in order to absorb the shock caused by the suddenrelease of pressure. The shock absorber may comprise, for example, anyconventional commercially available shock absorber adapted for use inwellbore operations.

[0152] Alternatively, or in combination, a mandrel catching structure isprovided in the end portion 260 of the tubular member 210 in order tocatch or at least decelerate the mandrel 205.

[0153] Once the extrusion process is completed, the expandable mandrel205 is removed from the wellbore 100. In a preferred embodiment, eitherbefore or after the removal of the expandable mandrel 205, the integrityof the fluidic seal of the overlapping joint between the upper portion260 of the tubular member 210 and the lower portion 270 of the casing115 is tested using conventional methods.

[0154] If the fluidic seal of the overlapping joint between the upperportion 260 of the tubular member 210 and the lower portion 270 of thecasing 115 is satisfactory, then any uncured portion of the material 305within the expanded tubular member 210 is then removed in a conventionalmanner such as, for example, circulating the uncured material out of theinterior of the expanded tubular member 210. The mandrel 205 is thenpulled out of the wellbore section 130 and a drill bit or mill is usedin combination with a conventional drilling assembly 505 to drill outany hardened material 305 within the tubular member 210. The material305 within the annular region 315 is then allowed to cure.

[0155] As illustrated in FIG. 5, preferably any remaining cured material305 within the interior of the expanded tubular member 210 is thenremoved in a conventional manner using a conventional drill string 505.The resulting new section of casing 510 includes the expanded tubularmember 210 and an outer annular layer 515 of cured material 305. Thebottom portion of the apparatus 200 comprising the shoe 215 and dart 405may then be removed by drilling out the shoe 215 and dart 405 usingconventional drilling methods.

[0156] In a preferred embodiment, as illustrated in FIG. 6, the upperportion 260 of the tubular member 210 includes one or more sealingmembers 605 and one or more pressure relief holes 610. In this manner,the overlapping joint between the lower portion 270 of the casing 115and the upper portion 260 of the tubular member 210 is pressure-tightand the pressure on the interior and exterior surfaces of the tubularmember 210 is equalized during the extrusion process.

[0157] In a preferred embodiment, the sealing members 605 are seatedwithin recesses 615 formed in the outer surface 265 of the upper portion260 of the tubular member 210. In an alternative preferred embodiment,the sealing members 605 are bonded or molded onto the outer surface 265of the upper portion 260 of the tubular member 210. The pressure reliefholes 610 are preferably positioned in the last few feet of the tubularmember 210. The pressure relief holes reduce the operating pressuresrequired to expand the upper portion 260 of the tubular member 210. Thisreduction in required operating pressure in turn reduces the velocity ofthe mandrel 205 upon the completion of the extrusion process. Thisreduction in velocity in turn minimizes the mechanical shock to theentire apparatus 200 upon the completion of the extrusion process.

[0158] Referring now to FIG. 7, a particularly preferred embodiment ofan apparatus 700 for forming a casing within a wellbore preferablyincludes an expandable mandrel or pig 705, an expandable mandrel or pigcontainer 710, a tubular member 715, a float shoe 720, a lower cup seal725, an upper cup seal 730, a fluid passage 735, a fluid passage 740, asupport member 745, a body of lubricant 750, an overshot connection 755,another support member 760, and a stabilizer 765.

[0159] The expandable mandrel 705 is coupled to and supported by thesupport member 745. The expandable mandrel 705 is further coupled to theexpandable mandrel container 710. The expandable mandrel 705 ispreferably adapted to controllably expand in a radial direction. Theexpandable mandrel 705 may comprise any number of conventionalcommercially available expandable mandrels modified in accordance withthe teachings of the present disclosure. In a preferred embodiment, theexpandable mandrel 705 comprises a hydraulic expansion toolsubstantially as disclosed in U.S. Pat. No. 5,348,095, the contents ofwhich are incorporated herein by reference, modified in accordance withthe teachings of the present disclosure.

[0160] The expandable mandrel container 710 is coupled to and supportedby the support member 745. The expandable mandrel container 710 isfurther coupled to the expandable mandrel 705. The expandable mandrelcontainer 710 may be constructed from any number of conventionalcommercially available materials such as, for example, Oilfield CountryTubular Goods, stainless steel, titanium or high strength steels. In apreferred embodiment, the expandable mandrel container 710 is fabricatedfrom material having a greater strength than the material from which thetubular member 715 is fabricated. In this manner, the container 710 canbe fabricated from a tubular material having a thinner wall thicknessthan the tubular member 210. This permits the container 710 to passthrough tight clearances thereby facilitating its placement within thewellbore.

[0161] In a preferred embodiment, once the expansion process begins, andthe thicker, lower strength material of the tubular member 715 isexpanded, the outside diameter of the tubular member 715 is greater thanthe outside diameter of the container 710.

[0162] The tubular member 715 is coupled to and supported by theexpandable mandrel 705. The tubular member 715 is preferably expanded inthe radial direction and extruded off of the expandable mandrel 705substantially as described above with reference to FIGS. 1-6. Thetubular member 715 may be fabricated from any number of materials suchas, for example, Oilfield Country Tubular Goods (OCTG), automotive gradesteel or plastics. In a preferred embodiment, the tubular member 715 isfabricated from OCTG.

[0163] In a preferred embodiment, the tubular member 715 has asubstantially annular cross-section. In a particularly preferredembodiment, the tubular member 715 has a substantially circular annularcross-section.

[0164] The tubular member 715 preferably includes an upper section 805,an intermediate section 810, and a lower section 815. The upper section805 of the tubular member 715 preferably is defined by the regionbeginning in the vicinity of the mandrel container 710 and ending withthe top section 820 of the tubular member 715. The intermediate section810 of the tubular member 715 is preferably defined by the regionbeginning in the vicinity of the top of the mandrel container 710 andending with the region in the vicinity of the mandrel 705. The lowersection of the tubular member 715 is preferably defined by the regionbeginning in the vicinity of the mandrel 705 and ending at the bottom825 of the tubular member 715.

[0165] In a preferred embodiment, the wall thickness of the uppersection 805 of the tubular member 715 is greater than the wallthicknesses of the intermediate and lower sections 810 and 815 of thetubular member 715 in order to optimally faciliate the initiation of theextrusion process and optimally permit the apparatus 700 to bepositioned in locations in the wellbore having tight clearances.

[0166] The outer diameter and wall thickness of the upper section 805 ofthe tubular member 715 may range, for example, from about 1.05 to 48inches and {fraction (1/8)} to 2 inches, respectively. In a preferredembodiment, the outer diameter and wall thickness of the upper section805 of the tubular member 715 range from about 3.5 to 16 inches and{fraction (3/8)} to 1.5 inches, respectively.

[0167] The outer diameter and wall thickness of the intermediate section810 of the tubular member 715 may range, for example, from about 2.5 to50 inches and {fraction (1/16)} to 1.5 inches, respectively. In apreferred embodiment, the outer diameter and wall thickness of theintermediate section 810 of the tubular member 715 range from about 3.5to 19 inches and {fraction (1/8)} to 1.25 inches, respectively.

[0168] The outer diameter and wall thickness of the lower section 815 ofthe tubular member 715 may range, for example, from about 2.5 to 50inches and {fraction (1/16)} to 1.25 inches, respectively. In apreferred embodiment, the outer diameter and wall thickness of the lowersection 810 of the tubular member 715 range from about 3.5 to 19 inchesand {fraction (1/8)} to 1.25 inches, respectively. In a particularlypreferred embodiment, the wall thickness of the lower section 815 of thetubular member 715 is further increased to increase the strength of theshoe 720 when drillable materials such as, for example, aluminum areused.

[0169] The tubular member 715 preferably comprises a solid tubularmember. In a preferred embodiment, the end portion 820 of the tubularmember 715 is slotted, perforated, or otherwise modified to catch orslow down the mandrel 705 when it completes the extrusion of tubularmember 715. In a preferred embodiment, the length of the tubular member715 is limited to minimize the possibility of buckling. For typicaltubular member 715 materials, the length of the tubular member 715 ispreferably limited to between about 40 to 20,000 feet in length.

[0170] The shoe 720 is coupled to the expandable mandrel 705 and thetubular member 715. The shoe 720 includes the fluid passage 740. In apreferred embodiment, the shoe 720 further includes an inlet passage830, and one or more jet ports 835. In a particularly preferredembodiment, the cross-sectional shape of the inlet passage 830 isadapted to receive a latch-down dart, or other similar elements, forblocking the inlet passage 830. The interior of the shoe 720 preferablyincludes a body of solid material 840 for increasing the strength of theshoe 720. In a particularly preferred embodiment, the body of solidmaterial 840 comprises aluminum.

[0171] The shoe 720 may comprise any number of conventional commerciallyavailable shoes such as, for example, Super Seal II Down-Jet float shoe,or guide shoe with a sealing sleeve for a latch down plug modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the shoe 720 comprises an aluminum down-jet guide shoe witha sealing sleeve for a latch-down plug available from Halliburton EnergyServices in Dallas, Tex., modified in accordance with the teachings ofthe present disclosure, in order to optimize guiding the tubular member715 in the wellbore, optimize the seal between the tubular member 715and an existing wellbore casing, and to optimally faciliate the removalof the shoe 720 by drilling it out after completion of the extrusionprocess.

[0172] The lower cup seal 725 is coupled to and supported by the supportmember 745. The lower cup seal 725 prevents foreign materials fromentering the interior region of the tubular member 715 above theexpandable mandrel 705. The lower cup seal 725 may comprise any numberof conventional commercially available cup seals such as, for example,TP cups or Selective Injection Packer (SIP) cups modified in accordancewith the teachings of the present disclosure. In a preferred embodiment,the lower cup seal 725 comprises a SIP cup, available from HalliburtonEnergy Services in Dallas, Tex. in order to optimally provide a debrisbarrier and hold a body of lubricant.

[0173] The upper cup seal 730 is coupled to and supported by the supportmember 760. The upper cup seal 730 prevents foreign materials fromentering the interior region of the tubular member 715. The upper cupseal 730 may comprise any number of conventional commercially availablecup seals such as, for example, TP cups or Selective Injection Packer(SIP) cup modified in accordance with the teachings of the presentdisclosure. In a preferred embodiment, the upper cup seal 730 comprisesa SIP cup available from Halliburton Energy Services in Dallas, Tex. inorder to optimally provide a debris barrier and contain a body oflubricant.

[0174] The fluid passage 735 permits fluidic materials to be transportedto and from the interior region of the tubular member 715 below theexpandable mandrel 705. The fluid passage 735 is fluidicly coupled tothe fluid passage 740. The fluid passage 735 is preferably coupled toand positioned within the support member 760, the support member 745,the mandrel container 710, and the expandable mandrel 705. The fluidpassage 735 preferably extends from a position adjacent to the surfaceto the bottom of the expandable mandrel 705. The fluid passage 735 ispreferably positioned along a centerline of the apparatus 700. The fluidpassage 735 is preferably selected to transport materials such ascement, drilling mud or epoxies at flow rates and pressures ranging fromabout 40 to 3,000 gallons/minute and 500 to 9,000 psi in order tooptimally provide sufficient operating pressures to extrude the tubularmember 715 off of the expandable mandrel 705.

[0175] As described above with reference to FIGS. 1-6, during placementof the apparatus 700 within a new section of a wellbore, fluidicmaterials forced up the fluid passage 735 can be released into thewellbore above the tubular member 715. In a preferred embodiment, theapparatus 700 further includes a pressure release passage that iscoupled to and positioned within the support member 260. The pressurerelease passage is further fluidicly coupled to the fluid passage 735.The pressure release passage preferably includes a control valve forcontrollably opening and closing the fluid passage. In a preferredembodiment, the control valve is pressure activated in order tocontrollably minimize surge pressures. The pressure release passage ispreferably positioned substantially orthogonal to the centerline of theapparatus 700. The pressure release passage is preferably selected toconvey materials such as cement, drilling mud or epoxies at flow ratesand pressures ranging from about 0 to 500 gallons/minute and 0 to 1,000psi in order to reduce the drag on the apparatus 700 during insertioninto a new section of a wellbore and to minimize surge pressures on thenew wellbore section.

[0176] The fluid passage 740 permits fluidic materials to be transportedto and from the region exterior to the tubular member 715. The fluidpassage 740 is preferably coupled to and positioned within the shoe 720in fluidic communication with the interior region of the tubular member715 below the expandable mandrel 705. The fluid passage 740 preferablyhas a cross-sectional shape that permits a plug, or other similardevice, to be placed in the inlet 830 of the fluid passage 740 tothereby block further passage of fluidic materials. In this manner, theinterior region of the tubular member 715 below the expandable mandrel705 can be optimally fluidicly isolated from the region exterior to thetubular member 715. This permits the interior region of the tubularmember 715 below the expandable mandrel 205 to be pressurized.

[0177] The fluid passage 740 is preferably positioned substantiallyalong the centerline of the apparatus 700. The fluid passage 740 ispreferably selected to convey materials such as cement, drilling mud orepoxies at flow rates and pressures ranging from about 0 to 3,000gallons/minute and 0 to 9,000 psi in order to optimally fill an annularregion between the tubular member 715 and a new section of a wellborewith fluidic materials. In a preferred embodiment, the fluid passage 740includes an inlet passage 830 having a geometry that can receive a dartand/or a ball sealing member. In this manner, the fluid passage 240 canbe sealed off by introducing a plug, dart and/or ball sealing elementsinto the fluid passage 230.

[0178] In a preferred embodiment, the apparatus 700 further includes oneor more seals 845 coupled to and supported by the end portion 820 of thetubular member 715. The seals 845 are further positioned on an outersurface of the end portion 820 of the tubular member 715. The seals 845permit the overlapping joint between an end portion of preexistingcasing and the end portion 820 of the tubular member 715 to be fluidiclysealed. The seals 845 may comprise any number of conventionalcommercially available seals such as, for example, lead, rubber, Teflon,or epoxy seals modified in accordance with the teachings of the presentdisclosure. In a preferred embodiment, the seals 845 comprise sealsmolded from StrataLock epoxy available from Halliburton Energy Servicesin Dallas, Tex. in order to optimally provide a hydraulic seal and aload bearing interference fit in the overlapping joint between thetubular member 715 and an existing casing with optimal load bearingcapacity to support the tubular member 715.

[0179] In a preferred embodiment, the seals 845 are selected to providea sufficient frictional force to support the expanded tubular member 715from the existing casing. In a preferred embodiment, the frictionalforce provided by the seals 845 ranges from about 1,000 to 1,000,000 lbfin order to optimally support the expanded tubular member 715.

[0180] The support member 745 is preferably coupled to the expandablemandrel 705 and the overshot connection 755. The support member 745preferably comprises an annular member having sufficient strength tocarry the apparatus 700 into a new section of a wellbore. The supportmember 745 may comprise any number of conventional commerciallyavailable support members such as, for example, steel drill pipe, coiledtubing or other high strength tubular modified in accordance with theteachings of the present disclosure. In a preferred embodiment, thesupport member 745 comprises conventional drill pipe available fromvarious steel mills in the United States.

[0181] In a preferred embodiment, a body of lubricant 750 is provided inthe annular region above the expandable mandrel container 710 within theinterior of the tubular member 715. In this manner, the extrusion of thetubular member 715 off of the expandable mandrel 705 is facilitated. Thelubricant 705 may comprise any number of conventional commerciallyavailable lubricants such as, for example, Lubriplate, chlorine basedlubricants, oil based lubricants, or Climax 1500 Antisieze (3100). In apreferred embodiment, the lubricant 750 comprises Climax 1500 Antisieze(3100) available from Halliburton Energy Services in Houston, Tex. inorder to optimally provide lubrication to faciliate the extrusionprocess.

[0182] The overshot connection 755 is coupled to the support member 745and the support member 760. The overshot connection 755 preferablypermits the support member 745 to be removably coupled to the supportmember 760. The overshot connection 755 may comprise any number ofconventional commercially available overshot connections such as, forexample, Innerstring Sealing Adapter, Innerstring Flat-Face SealingAdapter or EZ Drill Setting Tool Stinger. In a preferred embodiment, theovershot connection 755 comprises a Innerstring Adapter with an UpperGuide available from Halliburton Energy Services in Dallas, Tex.

[0183] The support member 760 is preferably coupled to the overshotconnection 755 and a surface support structure (not illustrated). Thesupport member 760 preferably comprises an annular member havingsufficient strength to carry the apparatus 700 into a new section of awellbore. The support member 760 may comprise any number of conventionalcommercially available support members such as, for example, steel drillpipe, coiled tubing or other high strength tubulars modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the support member 760 comprises a conventional drill pipeavailable from steel mills in the United States.

[0184] The stabilizer 765 is preferably coupled to the support member760. The stabilizer 765 also preferably stabilizes the components of theapparatus 700 within the tubular member 715. The stabilizer 765preferably comprises a spherical member having an outside diameter thatis about 80 to 99% of the interior diameter of the tubular member 715 inorder to optimally minimize buckling of the tubular member 715. Thestabilizer 765 may comprise any number of conventional commerciallyavailable stabilizers such as, for example, EZ Drill Star Guides, packershoes or drag blocks modified in accordance with the teachings of thepresent disclosure. In a preferred embodiment, the stabilizer 765comprises a sealing adapter upper guide available from HalliburtonEnergy Services in Dallas, Tex.

[0185] In a preferred embodiment, the support members 745 and 760 arethoroughly cleaned prior to assembly to the remaining portions of theapparatus 700. In this manner, the introduction of foreign material intothe apparatus 700 is minimized. This minimizes the possibility offoreign material clogging the various flow passages and valves of theapparatus 700.

[0186] In a preferred embodiment, before or after positioning theapparatus 700 within a new section of a wellbore, a couple of wellborevolumes are circulated through the various flow passages of theapparatus 700 in order to ensure that no foreign materials are locatedwithin the wellbore that might clog up the various flow passages andvalves of the apparatus 700 and to ensure that no foreign materialinterferes with the expansion mandrel 705 during the expansion process.

[0187] In a preferred embodiment, the apparatus 700 is operatedsubstantially as described above with reference to FIGS. 1-7 to form anew section of casing within a wellbore.

[0188] As illustrated in FIG. 8, in an alternative preferred embodiment,the method and apparatus described herein is used to repair an existingwellbore casing 805 by forming a tubular liner 810 inside of theexisting wellbore casing 805. In a preferred embodiment, an outerannular lining of cement is not provided in the repaired section. In thealternative preferred embodiment, any number of fluidic materials can beused to expand the tubular liner 810 into intimate contact with thedamaged section of the wellbore casing such as, for example, cement,epoxy, slag mix, or drilling mud. In the alternative preferredembodiment, sealing members 815 are preferably provided at both ends ofthe tubular member in order to optimally provide a fluidic seal. In analternative preferred embodiment, the tubular liner 810 is formed withina horizontally positioned pipeline section, such as those used totransport hydrocarbons or water, with the tubular liner 810 placed in anoverlapping relationship with the adjacent pipeline section. In thismanner, underground pipelines can be repaired without having to dig outand replace the damaged sections.

[0189] In another alternative preferred embodiment, the method andapparatus described herein is used to directly line a wellbore with atubular liner 810. In a preferred embodiment, an outer annular lining ofcement is not provided between the tubular liner 810 and the wellbore.In the alternative preferred embodiment, any number of fluidic materialscan be used to expand the tubular liner 810 into intimate contact withthe wellbore such as, for example, cement, epoxy, slag mix, or drillingmud.

[0190] Referring now to FIGS. 9, 9a, 9 b and 9 c, a preferred embodimentof an apparatus 900 for forming a wellbore casing includes an expandabletubular member 902, a support member 904, an expandable mandrel or pig906, and a shoe 908. In a preferred embodiment, the design andconstruction of the mandrel 906 and shoe 908 permits easy removal ofthose elements by drilling them out. In this manner, the assembly 900can be easily removed from a wellbore using a conventional drillingapparatus and corresponding drilling methods.

[0191] The expandable tubular member 902 preferably includes an upperportion 910, an intermediate portion 912 and a lower portion 914. Duringoperation of the apparatus 900, the tubular member 902 is preferablyextruded off of the mandrel 906 by pressurizing an interior region 966of the tubular member 902. The tubular member 902 preferably has asubstantially annular cross-section.

[0192] In a particularly preferred embodiment, an expandable tubularmember 915 is coupled to the upper portion 910 of the expandable tubularmember 902. During operation of the apparatus 900, the tubular member915 is preferably extruded off of the mandrel 906 by pressurizing theinterior region 966 of the tubular member 902. The tubular member 915preferably has a substantially annular cross-section. In a preferredembodiment, the wall thickness of the tubular member 915 is greater thanthe wall thickness of the tubular member 902.

[0193] The tubular member 915 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield tubulars, low alloy steels, titanium or stainless steels. In apreferred embodiment, the tubular member 915 is fabricated from oilfieldtubulars in order to optimally provide approximately the same mechanicalproperties as the tubular member 902. In a particularly preferredembodiment, the tubular member 915 has a plastic yield point rangingfrom about 40,000 to 135,000 psi in order to optimally provideapproximately the same yield properties as the tubular member 902. Thetubular member 915 may comprise a plurality of tubular members coupledend to end.

[0194] In a preferred embodiment, the upper end portion of the tubularmember 915 includes one or more sealing members for optimally providinga fluidic and/or gaseous seal with an existing section of wellborecasing.

[0195] In a preferred embodiment, the combined length of the tubularmembers 902 and 915 are limited to minimize the possibility of buckling.For typical tubular member materials, the combined length of the tubularmembers 902 and 915 are limited to between about 40 to 20,000 feet inlength.

[0196] The lower portion 914 of the tubular member 902 is preferablycoupled to the shoe 908 by a threaded connection 968. The intermediateportion 912 of the tubular member 902 preferably is placed in intimatesliding contact with the mandrel 906.

[0197] The tubular member 902 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield tubulars, low alloy steels, titanium or stainless steels. In apreferred embodiment, the tubular member 902 is fabricated from oilfieldtubulars in order to optimally provide approximately the same mechanicalproperties as the tubular member 915. In a particularly preferredembodiment, the tubular member 902 has a plastic yield point rangingfrom about 40,000 to 135,000 psi in order to optimally provideapproximately the same yield properties as the tubular member 915.

[0198] The wall thickness of the upper, intermediate, and lowerportions, 910, 912 and 914 of the tubular member 902 may range, forexample, from about {fraction (1/16)} to 1.5 inches. In a preferredembodiment, the wall thickness of the upper, intermediate, and lowerportions, 910, 912 and 914 of the tubular member 902 range from about{fraction (1/8)} to 1.25 in order to optimally provide wall thicknessthat are about the same as the tubular member 915. In a preferredembodiment, the wall thickness of the lower portion 914 is less than orequal to the wall thickness of the upper portion 910 in order tooptimally provide a geometry that will fit into tight clearancesdownhole.

[0199] The outer diameter of the upper, intermediate, and lowerportions, 910, 912 and 914 of the tubular member 902 may range, forexample, from about 1.05 to 48 inches. In a preferred embodiment, theouter diameter of the upper, intermediate, and lower portions, 910, 912and 914 of the tubular member 902 range from about 3½ to 19 inches inorder to optimally provide the ability to expand the most commonly usedoilfield tubulars.

[0200] The length of the tubular member 902 is preferably limited tobetween about 2 to 5 feet in order to optimally provide enough length tocontain the mandrel 906 and a body of lubricant.

[0201] The tubular member 902 may comprise any number of conventionalcommercially available tubular members modified in accordance with theteachings of the present disclosure. In a preferred embodiment, thetubular member 902 comprises Oilfield Country Tubular Goods availablefrom various U.S. steel mills. The tubular member 915 may comprise anynumber of conventional commercially available tubular members modifiedin accordance with the teachings of the present disclosure. In apreferred embodiment, the tubular member 915 comprises Oilfield CountryTubular Goods available from various U.S. steel mills.

[0202] The various elements of the tubular member 902 may be coupledusing any number of conventional process such as, for example, threadedconnections, welding or machined from one piece. In a preferredembodiment, the various elements of the tubular member 902 are coupledusing welding. The tubular member 902 may comprise a plurality oftubular elements that are coupled end to end. The various elements ofthe tubular member 915 may be coupled using any number of conventionalprocess such as, for example, threaded connections, welding or machinedfrom one piece. In a preferred embodiment, the various elements of thetubular member 915 are coupled using welding. The tubular member 915 maycomprise a plurality of tubular elements that are coupled end to end.The tubular members 902 and 915 may be coupled using any number ofconventional process such as, for example, threaded connections, weldingor machined from one piece.

[0203] The support member 904 preferably includes an innerstring adapter916, a fluid passage 918, an upper guide 920, and a coupling 922. Duringoperation of the apparatus 900, the support member 904 preferablysupports the apparatus 900 during movement of the apparatus 900 within awellbore. The support member 904 preferably has a substantially annularcross-section.

[0204] The support member 904 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield tubulars, low alloy steel, coiled tubing or stainless steel. Ina preferred embodiment, the support member 904 is fabricated from lowalloy steel in order to optimally provide high yield strength.

[0205] The innerstring adaptor 916 preferably is coupled to andsupported by a conventional drill string support from a surfacelocation. The innerstring adaptor 916 may be coupled to a conventionaldrill string support 971 by a threaded connection 970.

[0206] The fluid passage 918 is preferably used to convey fluids andother materials to and from the apparatus 900. In a preferredembodiment, the fluid passage 918 is fluidicly coupled to the fluidpassage 952. In a preferred embodiment, the fluid passage 918 is used toconvey hardenable fluidic sealing materials to and from the apparatus900. In a particularly preferred embodiment, the fluid passage 918 mayinclude one or more pressure relief passages (not illustrated) torelease fluid pressure during positioning of the apparatus 900 within awellbore. In a preferred embodiment, the fluid passage 918 is positionedalong a longitudinal centerline of the apparatus 900. In a preferredembodiment, the fluid passage 918 is selected to permit the conveyanceof hardenable fluidic materials at operating pressures ranging fromabout 0 to 9,000 psi.

[0207] The upper guide 920 is coupled to an upper portion of the supportmember 904. The upper guide 920 preferably is adapted to center thesupport member 904 within the tubular member 915. The upper guide 920may comprise any number of conventional guide members modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the upper guide 920 comprises an innerstring adapteravailable from Halliburton Energy Services in Dallas, Tex. order tooptimally guide the apparatus 900 within the tubular member 915.

[0208] The coupling 922 couples the support member 904 to the mandrel906. The coupling 922 preferably comprises a conventional threadedconnection.

[0209] The various elements of the support member 904 may be coupledusing any number of conventional processes such as, for example,welding, threaded connections or machined from one piece. In a preferredembodiment, the various elements of the support member 904 are coupledusing threaded connections.

[0210] The mandrel 906 preferably includes a retainer 924, a rubber cup926, an expansion cone 928, a lower cone retainer 930, a body of cement932, a lower guide 934, an extension sleeve 936, a spacer 938, a housing940, a sealing sleeve 942, an upper cone retainer 944, a lubricatormandrel 946, a lubricator sleeve 948, a guide 950, and a fluid passage952.

[0211] The retainer 924 is coupled to the lubricator mandrel 946,lubricator sleeve 948, and the rubber cup 926. The retainer 924 couplesthe rubber cup 926 to the lubricator sleeve 948. The retainer 924preferably has a substantially annular cross-section. The retainer 924may comprise any number of conventional commercially available retainerssuch as, for example, slotted spring pins or roll pin.

[0212] The rubber cup 926 is coupled to the retainer 924, the lubricatormandrel 946, and the lubricator sleeve 948. The rubber cup 926 preventsthe entry of foreign materials into the interior region 972 of thetubular member 902 below the rubber cup 926. The rubber cup 926 maycomprise any number of conventional commercially available rubber cupssuch as, for example, TP cups or Selective Injection Packer (SIP) cup.In a preferred embodiment, the rubber cup 926 comprises a SIP cupavailable from Halliburton Energy Services in Dallas, Tex. in order tooptimally block foreign materials.

[0213] In a particularly preferred embodiment, a body of lubricant isfurther provided in the interior region 972 of the tubular member 902 inorder to lubricate the interface between the exterior surface of themandrel 902 and the interior surface of the tubular members 902 and 915.The lubricant may comprise any number of conventional commerciallyavailable lubricants such as, for example, Lubriplate, chlorine basedlubricants, oil based lubricants or Climax 1500 Antiseize (3100). In apreferred embodiment, the lubricant comprises Climax 1500 Antiseize(3100) available from Climax Lubricants and Equipment Co. in Houston,Tex. in order to optimally provide lubrication to faciliate theextrusion process.

[0214] The expansion cone 928 is coupled to the lower cone retainer 930,the body of cement 932, the lower guide 934, the extension sleeve 936,the housing 940, and the upper cone retainer 944. In a preferredembodiment, during operation of the apparatus 900, the tubular members902 and 915 are extruded off of the outer surface of the expansion cone928. In a preferred embodiment, axial movement of the expansion cone 928is prevented by the lower cone retainer 930, housing 940 and the uppercone retainer 944. Inner radial movement of the expansion cone 928 isprevented by the body of cement 932, the housing 940, and the upper coneretainer 944.

[0215] The expansion cone 928 preferably has a substantially annularcross section. The outside diameter of the expansion cone 928 ispreferably tapered to provide a cone shape. The wall thickness of theexpansion cone 928 may range, for example, from about 0.125 to 3 inches.In a preferred embodiment, the wall thickness of the expansion cone 928ranges from about 0.25 to 0.75 inches in order to optimally provideadequate compressive strength with minimal material. The maximum andminimum outside diameters of the expansion cone 928 may range, forexample, from about 1 to 47 inches. In a preferred embodiment, themaximum and minimum outside diameters of the expansion cone 928 rangefrom about 3.5 to 19 in order to optimally provide expansion ofgenerally available oilfield tubulars

[0216] The expansion cone 928 may be fabricated from any number ofconventional commercially available materials such as, for example,ceramic, tool steel, titanium or low alloy steel. In a preferredembodiment, the expansion cone 928 is fabricated from tool steel inorder to optimally provide high strength and abrasion resistance. Thesurface hardness of the outer surface of the expansion cone 928 mayrange, for example, from about 50 Rockwell C to 70 Rockwell C. In apreferred embodiment, the surface hardness of the outer surface of theexpansion cone 928 ranges from about 58 Rockwell C to 62 Rockwell C inorder to optimally provide high yield strength. In a preferredembodiment, the expansion cone 928 is heat treated to optimally providea hard outer surface and a resilient interior body in order to optimallyprovide abrasion resistance and fracture toughness.

[0217] The lower cone retainer 930 is coupled to the expansion cone 928and the housing 940. In a preferred embodiment, axial movement of theexpansion cone 928 is prevented by the lower cone retainer 930.Preferably, the lower cone retainer 930 has a substantially annularcross-section.

[0218] The lower cone retainer 930 may be fabricated from any number ofconventional commercially available materials such as, for example,ceramic, tool steel, titanium or low alloy steel. In a preferredembodiment, the lower cone retainer 930 is fabricated from tool steel inorder to optimally provide high strength and abrasion resistance. Thesurface hardness of the outer surface of the lower cone retainer 930 mayrange, for example, from about 50 Rockwell C to 70 Rockwell C. In apreferred embodiment, the surface hardness of the outer surface of thelower cone retainer 930 ranges from about 58 Rockwell C to 62 Rockwell Cin order to optimally provide high yield strength. In a preferredembodiment, the lower cone retainer 930 is heat treated to optimallyprovide a hard outer surface and a resilient interior body in order tooptimally provide abrasion resistance and fracture toughness.

[0219] In a preferred embodiment, the lower cone retainer 930 and theexpansion cone 928 are formed as an integral one-piece element in orderreduce the number of components and increase the overall strength of theapparatus. The outer surface of the lower cone retainer 930 preferablymates with the inner surfaces of the tubular members 902 and 915.

[0220] The body of cement 932 is positioned within the interior of themandrel 906. The body of cement 932 provides an inner bearing structurefor the mandrel 906. The body of cement 932 further may be easilydrilled out using a conventional drill device. In this manner, themandrel 906 may be easily removed using a conventional drilling device.

[0221] The body of cement 932 may comprise any number of conventionalcommercially available cement compounds. Alternatively, aluminum, castiron or some other drillable metallic, composite, or aggregate materialmay be substituted for cement. The body of cement 932 preferably has asubstantially annular cross-section.

[0222] The lower guide 934 is coupled to the extension sleeve 936 andhousing 940. During operation of the apparatus 900, the lower guide 934preferably helps guide the movement of the mandrel 906 within thetubular member 902. The lower guide 934 preferably has a substantiallyannular cross-section.

[0223] The lower guide 934 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield tubulars, low alloy steel or stainless steel. In a preferredembodiment, the lower guide 934 is fabricated from low alloy steel inorder to optimally provide high yield strength. The outer surface of thelower guide 934 preferably mates with the inner surface of the tubularmember 902 to provide a sliding fit.

[0224] The extension sleeve 936 is coupled to the lower guide 934 andthe housing 940. During operation of the apparatus 900, the extensionsleeve 936 preferably helps guide the movement of the mandrel 906 withinthe tubular member 902. The extension sleeve 936 preferably has asubstantially annular cross-section.

[0225] The extension sleeve 936 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield tubulars, low alloy steel or stainless steel. In a preferredembodiment, the extension sleeve 936 is fabricated from low alloy steelin order to optimally provide high yield strength. The outer surface ofthe extension sleeve 936 preferably mates with the inner surface of thetubular member 902 to provide a sliding fit. In a preferred embodiment,the extension sleeve 936 and the lower guide 934 are formed as anintegral one-piece element in order to minimize the number of componentsand increase the strength of the apparatus.

[0226] The spacer 938 is coupled to the sealing sleeve 942. The spacer938 preferably includes the fluid passage 952 and is adapted to matewith the extension tube 960 of the shoe 908. In this manner, a plug ordart can be conveyed from the surface through the fluid passages 918 and952 into the fluid passage 962. Preferably, the spacer 938 has asubstantially annular cross-section.

[0227] The spacer 938 may be fabricated from any number of conventionalcommercially available materials such as, for example, steel, aluminumor cast iron. In a preferred embodiment, the spacer 938 is fabricatedfrom aluminum in order to optimally provide drillability. The end of thespacer 938 preferably mates with the end of the extension tube 960. In apreferred embodiment, the spacer 938 and the sealing sleeve 942 areformed as an integral one-piece element in order to reduce the number ofcomponents and increase the strength of the apparatus.

[0228] The housing 940 is coupled to the lower guide 934, extensionsleeve 936, expansion cone 928, body of cement 932, and lower coneretainer 930. During operation of the apparatus 900, the housing 940preferably prevents inner radial motion of the expansion cone 928.Preferably, the housing 940 has a substantially annular cross-section.

[0229] The housing 940 may be fabricated from any number of conventionalcommercially available materials such as, for example, oilfieldtubulars, low alloy steel or stainless steel. In a preferred embodiment,the housing 940 is fabricated from low alloy steel in order to optimallyprovide high yield strength. In a preferred embodiment, the lower guide934, extension sleeve 936 and housing 940 are formed as an integralone-piece element in order to minimize the number of components andincrease the strength of the apparatus.

[0230] In a particularly preferred embodiment, the interior surface ofthe housing 940 includes one or more protrusions to faciliate theconnection between the housing 940 and the body of cement 932.

[0231] The sealing sleeve 942 is coupled to the support member 904, thebody of cement 932, the spacer 938, and the upper cone retainer 944.During operation of the apparatus, the sealing sleeve 942 preferablyprovides support for the mandrel 906. The sealing sleeve 942 ispreferably coupled to the support member 904 using the coupling 922.Preferably, the sealing sleeve 942 has a substantially annularcross-section.

[0232] The sealing sleeve 942 may be fabricated from any number ofconventional commercially available materials such as, for example,steel, aluminum or cast iron. In a preferred embodiment, the sealingsleeve 942 is fabricated from aluminum in order to optimally providedrillability of the sealing sleeve 942.

[0233] In a particularly preferred embodiment, the outer surface of thesealing sleeve 942 includes one or more protrusions to faciliate theconnection between the sealing sleeve 942 and the body of cement 932.

[0234] In a particularly preferred embodiment, the spacer 938 and thesealing sleeve 942 are integrally formed as a one-piece element in orderto minimize the number of components.

[0235] The upper cone retainer 944 is coupled to the expansion cone 928,the sealing sleeve 942, and the body of cement 932. During operation ofthe apparatus 900, the upper cone retainer 944 preferably prevents axialmotion of the expansion cone 928. Preferably, the upper cone retainer944 has a substantially annular cross-section.

[0236] The upper cone retainer 944 may be fabricated from any number ofconventional commercially available materials such as, for example,steel, aluminum or cast iron. In a preferred embodiment, the upper coneretainer 944 is fabricated from aluminum in order to optimally providedrillability of the upper cone retainer 944.

[0237] In a particularly preferred embodiment, the upper cone retainer944 has a cross-sectional shape designed to provide increased rigidity.In a particularly preferred embodiment, the upper cone retainer 944 hasa cross-sectional shape that is substantially I-shaped to provideincreased rigidity and minimize the amount of material that would haveto be drilled out.

[0238] The lubricator mandrel 946 is coupled to the retainer 924, therubber cup 926, the upper cone retainer 944, the lubricator sleeve 948,and the guide 950. During operation of the apparatus 900, the lubricatormandrel 946 preferably contains the body of lubricant in the annularregion 972 for lubricating the interface between the mandrel 906 and thetubular member 902. Preferably, the lubricator mandrel 946 has asubstantially annular cross-section.

[0239] The lubricator mandrel 946 may be fabricated from any number ofconventional commercially available materials such as, for example,steel, aluminum or cast iron. In a preferred embodiment, the lubricatormandrel 946 is fabricated from aluminum in order to optimally providedrillability of the lubricator mandrel 946.

[0240] The lubricator sleeve 948 is coupled to the lubricator mandrel946, the retainer 924, the rubber cup 926, the upper cone retainer 944,the lubricator sleeve 948, and the guide 950. During operation of theapparatus 900, the lubricator sleeve 948 preferably supports the rubbercup 926. Preferably, the lubricator sleeve 948 has a substantiallyannular cross-section.

[0241] The lubricator sleeve 948 may be fabricated from any number ofconventional commercially available materials such as, for example,steel, aluminum or cast iron. In a preferred embodiment, the lubricatorsleeve 948 is fabricated from aluminum in order to optimally providedrillability of the lubricator sleeve 948.

[0242] As illustrated in FIG. 9c, the lubricator sleeve 948 is supportedby the lubricator mandrel 946. The lubricator sleeve 948 in turnsupports the rubber cup 926. The retainer 924 couples the rubber cup 926to the lubricator sleeve 948. In a preferred embodiment, seals 949 a and949 b are provided between the lubricator mandrel 946, lubricator sleeve948, and rubber cup 926 in order to optimally seal off the interiorregion 972 of the tubular member 902.

[0243] The guide 950 is coupled to the lubricator mandrel 946, theretainer 924, and the lubricator sleeve 948. During operation of theapparatus 900, the guide 950 preferably guides the apparatus on thesupport member 904. Preferably, the guide 950 has a substantiallyannular cross-section.

[0244] The guide 950 may be fabricated from any number of conventionalcommercially available materials such as, for example, steel, aluminumor cast iron. In a preferred embodiment, the guide 950 is fabricatedfrom aluminum order to optimally provide drillability of the guide 950.

[0245] The fluid passage 952 is coupled to the mandrel 906. Duringoperation of the apparatus, the fluid passage 952 preferably conveyshardenable fluidic materials. In a preferred embodiment, the fluidpassage 952 is positioned about the centerline of the apparatus 900. Ina particularly preferred embodiment, the fluid passage 952 is adapted toconvey hardenable fluidic materials at pressures and flow rate rangingfrom about 0 to 9,000 psi and 0 to 3,000 gallons/min in order tooptimally provide pressures and flow rates to displace and circulatefluids during the installation of the apparatus 900.

[0246] The various elements of the mandrel 906 may be coupled using anynumber of conventional process such as, for example, threadedconnections, welded connections or cementing. In a preferred embodiment,the various elements of the mandrel 906 are coupled using threadedconnections and cementing.

[0247] The shoe 908 preferably includes a housing 954, a body of cement956, a sealing sleeve 958, an extension tube 960, a fluid passage 962,and one or more outlet jets 964.

[0248] The housing 954 is coupled to the body of cement 956 and thelower portion 914 of the tubular member 902. During operation of theapparatus 900, the housing 954 preferably couples the lower portion ofthe tubular member 902 to the shoe 908 to facilitate the extrusion andpositioning of the tubular member 902. Preferably, the housing 954 has asubstantially annular cross-section.

[0249] The housing 954 may be fabricated from any number of conventionalcommercially available materials such as, for example, steel oraluminum. In a preferred embodiment, the housing 954 is fabricated fromaluminum in order to optimally provide drillability of the housing 954.

[0250] In a particularly preferred embodiment, the interior surface ofthe housing 954 includes one or more protrusions to faciliate theconnection between the body of cement 956 and the housing 954.

[0251] The body of cement 956 is coupled to the housing 954, and thesealing sleeve 958. In a preferred embodiment, the composition of thebody of cement 956 is selected to permit the body of cement to be easilydrilled out using conventional drilling machines and processes.

[0252] The composition of the body of cement 956 may include any numberof conventional cement compositions. In an alternative embodiment, adrillable material such as, for example, aluminum or iron may besubstituted for the body of cement 956.

[0253] The sealing sleeve 958 is coupled to the body of cement 956, theextension tube 960, the fluid passage 962, and one or more outlet jets964. During operation of the apparatus 900, the sealing sleeve 958preferably is adapted to convey a hardenable fluidic material from thefluid passage 952 into the fluid passage 962 and then into the outletjets 964 in order to inject the hardenable fluidic material into anannular region external to the tubular member 902. In a preferredembodiment, during operation of the apparatus 900, the sealing sleeve958 further includes an inlet geometry that permits a conventional plugor dart 974 to become lodged in the inlet of the sealing sleeve 958. Inthis manner, the fluid passage 962 may be blocked thereby fluidiclyisolating the interior region 966 of the tubular member 902.

[0254] In a preferred embodiment, the sealing sleeve 958 has asubstantially annular cross-section. The sealing sleeve 958 may befabricated from any number of conventional commercially availablematerials such as, for example, steel, aluminum or cast iron. In apreferred embodiment, the sealing sleeve 958 is fabricated from aluminumin order to optimally provide drillability of the sealing sleeve 958.

[0255] The extension tube 960 is coupled to the sealing sleeve 958, thefluid passage 962, and one or more outlet jets 964. During operation ofthe apparatus 900, the extension tube 960 preferably is adapted toconvey a hardenable fluidic material from the fluid passage 952 into thefluid passage 962 and then into the outlet jets 964 in order to injectthe hardenable fluidic material into an annular region external to thetubular member 902. In a preferred embodiment, during operation of theapparatus 900, the sealing sleeve 960 further includes an inlet geometrythat permits a conventional plug or dart 974 to become lodged in theinlet of the sealing sleeve 958. In this manner, the fluid passage 962is blocked thereby fluidicly isolating the interior region 966 of thetubular member 902. In a preferred embodiment, one end of the extensiontube 960 mates with one end of the spacer 938 in order to optimallyfaciliate the transfer of material between the two.

[0256] In a preferred embodiment, the extension tube 960 has asubstantially annular cross-section. The extension tube 960 may befabricated from any number of conventional commercially availablematerials such as, for example, steel, aluminum or cast iron. In apreferred embodiment, the extension tube 960 is fabricated from aluminumin order to optimally provide drillability of the extension tube 960.

[0257] The fluid passage 962 is coupled to the sealing sleeve 958, theextension tube 960, and one or more outlet jets 964. During operation ofthe apparatus 900, the fluid passage 962 is preferably conveyshardenable fluidic materials. In a preferred embodiment, the fluidpassage 962 is positioned about the centerline of the apparatus 900. Ina particularly preferred embodiment, the fluid passage 962 is adapted toconvey hardenable fluidic materials at pressures and flow rate rangingfrom about 0 to 9,000 psi and 0 to 3,000 gallons/min in order tooptimally provide fluids at operationally efficient rates.

[0258] The outlet jets 964 are coupled to the sealing sleeve 958, theextension tube 960, and the fluid passage 962. During operation of theapparatus 900, the outlet jets 964 preferably convey hardenable fluidicmaterial from the fluid passage 962 to the region exterior of theapparatus 900. In a preferred embodiment, the shoe 908 includes aplurality of outlet jets 964.

[0259] In a preferred embodiment, the outlet jets 964 comprise passagesdrilled in the housing 954 and the body of cement 956 in order tosimplify the construction of the apparatus 900.

[0260] The various elements of the shoe 908 may be coupled using anynumber of conventional process such as, for example, threadedconnections, cement or machined from one piece of material. In apreferred embodiment, the various elements of the shoe 908 are coupledusing cement.

[0261] In a preferred embodiment, the assembly 900 is operatedsubstantially as described above with reference to FIGS. 1-8 to create anew section of casing in a wellbore or to repair a wellbore casing orpipeline.

[0262] In particular, in order to extend a wellbore into a subterraneanformation, a drill string is used in a well known manner to drill outmaterial from the subterranean formation to form a new section.

[0263] The apparatus 900 for forming a wellbore casing in a subterraneanformation is then positioned in the new section of the wellbore. In aparticularly preferred embodiment, the apparatus 900 includes thetubular member 915. In a preferred embodiment, a hardenable fluidicsealing hardenable fluidic sealing material is then pumped from asurface location into the fluid passage 918. The hardenable fluidicsealing material then passes from the fluid passage 918 into theinterior region 966 of the tubular member 902 below the mandrel 906. Thehardenable fluidic sealing material then passes from the interior region966 into the fluid passage 962. The hardenable fluidic sealing materialthen exits the apparatus 900 via the outlet jets 964 and fills anannular region between the exterior of the tubular member 902 and theinterior wall of the new section of the wellbore. Continued pumping ofthe hardenable fluidic sealing material causes the material to fill upat least a portion of the annular region.

[0264] The hardenable fluidic sealing material is preferably pumped intothe annular region at pressures and flow rates ranging, for example,from about 0 to 5,000 psi and 0 to 1,500 gallons/min, respectively. In apreferred embodiment, the hardenable fluidic sealing material is pumpedinto the annular region at pressures and flow rates that are designedfor the specific wellbore section in order to optimize the displacementof the hardenable fluidic sealing material while not creating highenough circulating pressures such that circulation might be lost andthat could cause the wellbore to collapse. The optimum pressures andflow rates are preferably determined using conventional empiricalmethods.

[0265] The hardenable fluidic sealing material may comprise any numberof conventional commercially available hardenable fluidic sealingmaterials such as, for example, slag mix, cement or epoxy. In apreferred embodiment, the hardenable fluidic sealing material comprisesblended cements designed specifically for the well section being linedavailable from Halliburton Energy Services in Dallas, Tex. in order tooptimally provide support for the new tubular member while alsomaintaining optimal flow characteristics so as to minimize operationaldifficulties during the displacement of the cement in the annularregion. The optimum composition of the blended cements is preferablydetermined using conventional empirical methods.

[0266] The annular region preferably is filled with the hardenablefluidic sealing material in sufficient quantities to ensure that, uponradial expansion of the tubular member 902, the annular region of thenew section of the wellbore will be filled with hardenable material.

[0267] Once the annular region has been adequately filled withhardenable fluidic sealing material, a plug or dart 974, or othersimilar device, preferably is introduced into the fluid passage 962thereby fluidicly isolating the interior region 966 of the tubularmember 902 from the external annular region. In a preferred embodiment,a non hardenable fluidic material is then pumped into the interiorregion 966 causing the interior region 966 to pressurize. In aparticularly preferred embodiment, the plug or dart 974, or othersimilar device, preferably is introduced into the fluid passage 962 byintroducing the plug or dart 974, or other similar device into the nonhardenable fluidic material. In this manner, the amount of curedmaterial within the interior of the tubular members 902 and 915 isminimized.

[0268] Once the interior region 966 becomes sufficiently pressurized,the tubular members 902 and 915 are extruded off of the mandrel 906. Themandrel 906 may be fixed or it may be expandable. During the extrusionprocess, the mandrel 906 is raised out of the expanded portions of thetubular members 902 and 915 using the support member 904. During thisextrusion process, the shoe 908 is preferably substantially stationary.

[0269] The plug or dart 974 is preferably placed into the fluid passage962 by introducing the plug or dart 974 into the fluid passage 918 at asurface location in a conventional manner. The plug or dart 974 maycomprise any number of conventional commercially available devices forplugging a fluid passage such as, for example, Multiple Stage Cementer(MSC) latch-down plug, Omega latch-down plug or three-wiper latch downplug modified in accordance with the teachings of the presentdisclosure. In a preferred embodiment, the plug or dart 974 comprises aMSC latch-down plug available from Halliburton Energy Services inDallas, Tex.

[0270] After placement of the plug or dart 974 in the fluid passage 962,the non hardenable fluidic material is preferably pumped into theinterior region 966 at pressures and flow rates ranging fromapproximately 500 to 9,000 psi and 40 to 3,000 gallons/min in order tooptimally extrude the tubular members 902 and 915 off of the mandrel906.

[0271] For typical tubular members 902 and 915, the extrusion of thetubular members 902 and 915 off of the expandable mandrel will beginwhen the pressure of the interior region 966 reaches approximately 500to 9,000 psi. In a preferred embodiment, the extrusion of the tubularmembers 902 and 915 off of the mandrel 906 begins when the pressure ofthe interior region 966 reaches approximately 1,200 to 8,500 psi with aflow rate of about 40 to 1250 gallons/minute.

[0272] During the extrusion process, the mandrel 906 may be raised outof the expanded portions of the tubular members 902 and 915 at ratesranging, for example, from about 0 to 5 ft/sec. In a preferredembodiment, during the extrusion process, the mandrel 906 is raised outof the expanded portions of the tubular members 902 and 915 at ratesranging from about 0 to 2 ft/sec in order to optimally provide pullingspeed fast enough to permit efficient operation and permit fullexpansion of the tubular members 902 and 915 prior to curing of thehardenable fluidic sealing material; but not so fast that timelyadjustment of operating parameters during operation is prevented.

[0273] When the upper end portion of the tubular member 915 is extrudedoff of the mandrel 906, the outer surface of the upper end portion ofthe tubular member 915 will preferably contact the interior surface ofthe lower end portion of the existing casing to form an fluid tightoverlapping joint. The contact pressure of the overlapping joint mayrange, for example, from approximately 50 to 20,000 psi. In a preferredembodiment, the contact pressure of the overlapping joint between theupper end of the tubular member 915 and the existing section of wellborecasing ranges from approximately 400 to 10,000 psi in order to optimallyprovide contact pressure to activate the sealing members and provideoptimal resistance such that the tubular member 915 and existingwellbore casing will carry typical tensile and compressive loads.

[0274] In a preferred embodiment, the operating pressure and flow rateof the non hardenable fluidic material will be controllably ramped downwhen the mandrel 906 reaches the upper end portion of the tubular member915. In this manner, the sudden release of pressure caused by thecomplete extrusion of the tubular member 915 off of the expandablemandrel 906 can be minimized. In a preferred embodiment, the operatingpressure is reduced in a substantially linear fashion from 100% to about10% during the end of the extrusion process beginning when the mandrel906 has completed approximately all but about the last 5 feet of theextrusion process.

[0275] In an alternative preferred embodiment, the operating pressureand/or flow rate of the hardenable fluidic sealing material and/or thenon hardenable fluidic material are controlled during all phases of theoperation of the apparatus 900 to minimize shock.

[0276] Alternatively, or in combination, a shock absorber is provided inthe support member 904 in order to absorb the shock caused by the suddenrelease of pressure.

[0277] Alternatively, or in combination, a mandrel catching structure isprovided above the support member 904 in order to catch or at leastdecelerate the mandrel 906.

[0278] Once the extrusion process is completed, the mandrel 906 isremoved from the wellbore. In a preferred embodiment, either before orafter the removal of the mandrel 906, the integrity of the fluidic sealof the overlapping joint between the upper portion of the tubular member915 and the lower portion of the existing casing is tested usingconventional methods. If the fluidic seal of the overlapping jointbetween the upper portion of the tubular member 915 and the lowerportion of the existing casing is satisfactory, then the uncured portionof any of the hardenable fluidic sealing material within the expandedtubular member 915 is then removed in a conventional manner. Thehardenable fluidic sealing material within the annular region betweenthe expanded tubular member 915 and the existing casing and new sectionof wellbore is then allowed to cure.

[0279] Preferably any remaining cured hardenable fluidic sealingmaterial within the interior of the expanded tubular members 902 and 915is then removed in a conventional manner using a conventional drillstring. The resulting new section of casing preferably includes theexpanded tubular members 902 and 915 and an outer annular layer of curedhardenable fluidic sealing material. The bottom portion of the apparatus900 comprising the shoe 908 may then be removed by drilling out the shoe908 using conventional drilling methods.

[0280] In an alternative embodiment, during the extrusion process, itmay be necessary to remove the entire apparatus 900 from the interior ofthe wellbore due to a malfunction. In this circumstance, a conventionaldrill string is used to drill out the interior sections of the apparatus900 in order to facilitate the removal of the remaining sections. In apreferred embodiment, the interior elements of the apparatus 900 arefabricated from materials such as, for example, cement and aluminum,that permit a conventional drill string to be employed to drill out theinterior components.

[0281] In particular, in a preferred embodiment, the composition of theinterior sections of the mandrel 906 and shoe 908, including one or moreof the body of cement 932, the spacer 938, the sealing sleeve 942, theupper cone retainer 944, the lubricator mandrel 946, the lubricatorsleeve 948, the guide 950, the housing 954, the body of cement 956, thesealing sleeve 958, and the extension tube 960, are selected to permitat least some of these components to be drilled out using conventionaldrilling methods and apparatus. In this manner, in the event of amalfunction downhole, the apparatus 900 may be easily removed from thewellbore.

[0282] Referring now to FIGS. 10a, 10 b, 10 c, 10 d, 10 e, 10 f, and 10g a method and apparatus for creating a tie-back liner in a wellborewill now be described. As illustrated in FIG. 10a, a wellbore 1000positioned in a subterranean formation 1002 includes a first casing 1004and a second casing 1006.

[0283] The first casing 1004 preferably includes a tubular liner 1008and a cement annulus 1010. The second casing 1006 preferably includes atubular liner 1012 and a cement annulus 1014. In a preferred embodiment,the second casing 1006 is formed by expanding a tubular membersubstantially as described above with reference to FIGS. 1-9 c or belowwith reference to FIGS. 11a-11 f.

[0284] In a particularly preferred embodiment, an upper portion of thetubular liner 1012 overlaps with a lower portion of the tubular liner1008. In a particularly preferred embodiment, an outer surface of theupper portion of the tubular liner 1012 includes one or more sealingmembers 1016 for providing a fluidic seal between the tubular liners1008 and 1012.

[0285] Referring to FIG. 10b, in order to create a tie-back liner thatextends from the overlap between the first and second casings, 1004 and1006, an apparatus 1100 is preferably provided that includes anexpandable mandrel or pig 1105, a tubular member 1110, a shoe 1115, oneor more cup seals 1120, a fluid passage 1130, a fluid passage 1135, oneor more fluid passages 1140, seals 1145, and a support member 1150.

[0286] The expandable mandrel or pig 1105 is coupled to and supported bythe support member 1150. The expandable mandrel 1105 is preferablyadapted to controllably expand in a radial direction. The expandablemandrel 1105 may comprise any number of conventional commerciallyavailable expandable mandrels modified in accordance with the teachingsof the present disclosure. In a preferred embodiment, the expandablemandrel 1105 comprises a hydraulic expansion tool substantially asdisclosed in U.S. Pat. No. 5,348,095, the disclosure of which isincorporated herein by reference, modified in accordance with theteachings of the present disclosure.

[0287] The tubular member 1110 is coupled to and supported by theexpandable mandrel 1105. The tubular member 1105 is expanded in theradial direction and extruded off of the expandable mandrel 1105. Thetubular member 1110 may be fabricated from any number of materials suchas, for example, Oilfield Country Tubular Goods, 13 chromium tubing orplastic piping. In a preferred embodiment, the tubular member 1110 isfabricated from Oilfield Country Tubular Goods.

[0288] The inner and outer diameters of the tubular member 1110 mayrange, for example, from approximately 0.75 to 47 inches and 1.05 to 48inches, respectively. In a preferred embodiment, the inner and outerdiameters of the tubular member 1110 range from about 3 to 15.5 inchesand 3.5 to 16 inches, respectively in order to optimally providecoverage for typical oilfield casing sizes. The tubular member 1110preferably comprises a solid member.

[0289] In a preferred embodiment, the upper end portion of the tubularmember 1110 is slotted, perforated, or otherwise modified to catch orslow down the mandrel 1105 when it completes the extrusion of tubularmember 1110. In a preferred embodiment, the length of the tubular member1110 is limited to minimize the possibility of buckling. For typicaltubular member 1110 materials, the length of the tubular member 1110 ispreferably limited to between about 40 to 20,000 feet in length.

[0290] The shoe 1115 is coupled to the expandable mandrel 1105 and thetubular member 1110. The shoe 1115 includes the fluid passage 1135. Theshoe 1115 may comprise any number of conventional commercially availableshoes such as, for example, Super Seal II float shoe, Super Seal IIDown-Jet float shoe or a guide shoe with a sealing sleeve for a latchdown plug modified in accordance with the teachings of the presentdisclosure. In a preferred embodiment, the shoe 1115 comprises analuminum down-jet guide shoe with a sealing sleeve for a latch-down plugwith side ports radiating off of the exit flow port available fromHalliburton Energy Services in Dallas, Tex., modified in accordance withthe teachings of the present disclosure, in order to optimally guide thetubular member 1100 to the overlap between the tubular member 1100 andthe casing 1012, optimally fluidicly isolate the interior of the tubularmember 1100 after the latch down plug has seated, and optimally permitdrilling out of the shoe 1115 after completion of the expansion andcementing operations.

[0291] In a preferred embodiment, the shoe 1115 includes one or moreside outlet ports 1140 in fluidic communication with the fluid passage1135. In this manner, the shoe 1115 injects hardenable fluidic sealingmaterial into the region outside the shoe 1115 and tubular member 1110.In a preferred embodiment, the shoe 1115 includes one or more of thefluid passages 1140 each having an inlet geometry that can receive adart and/or a ball sealing member. In this manner, the fluid passages1140 can be sealed off by introducing a plug, dart and/or ball sealingelements into the fluid passage 1130.

[0292] The cup seal 1120 is coupled to and supported by the supportmember 1150. The cup seal 1120 prevents foreign materials from enteringthe interior region of the tubular member 1110 adjacent to theexpandable mandrel 1105. The cup seal 1120 may comprise any number ofconventional commercially available cup seals such as, for example, TPcups or Selective Injection Packer (SIP) cups modified in accordancewith the teachings of the present disclosure. In a preferred embodiment,the cup seal 1120 comprises a SIP cup, available from Halliburton EnergyServices in Dallas, Tex. in order to optimally provide a barrier todebris and contain a body of lubricant.

[0293] The fluid passage 1130 permits fluidic materials to betransported to and from the interior region of the tubular member 1110below the expandable mandrel 1105. The fluid passage 1130 is coupled toand positioned within the support member 1150 and the expandable mandrel1105. The fluid passage 1130 preferably extends from a position adjacentto the surface to the bottom of the expandable mandrel 1105. The fluidpassage 1130 is preferably positioned along a centerline of theapparatus 1100. The fluid passage 1130 is preferably selected totransport materials such as cement, drilling mud or epoxies at flowrates and pressures ranging from about 0 to 3,000 gallons/minute and 0to 9,000 psi in order to optimally provide sufficient operatingpressures to circulate fluids at operationally efficient rates.

[0294] The fluid passage 1135 permits fluidic materials to betransmitted from fluid passage 1130 to the interior of the tubularmember 1110 below the mandrel 1105.

[0295] The fluid passages 1140 permits fluidic materials to betransported to and from the region exterior to the tubular member 1110and shoe 1115. The fluid passages 1140 are coupled to and positionedwithin the shoe 1115 in fluidic communication with the interior regionof the tubular member 1110 below the expandable mandrel 1105. The fluidpassages 1140 preferably have a cross-sectional shape that permits aplug, or other similar device, to be placed in the fluid passages 1140to thereby block further passage of fluidic materials. In this manner,the interior region of the tubular member 1110 below the expandablemandrel 1105 can be fluidicly isolated from the region exterior to thetubular member 1105. This permits the interior region of the tubularmember 1110 below the expandable mandrel 1105 to be pressurized.

[0296] The fluid passages 1140 are preferably positioned along theperiphery of the shoe 1115. The fluid passages 1140 are preferablyselected to convey materials such as cement, drilling mud or epoxies atflow rates and pressures ranging from about 0 to 3,000 gallons/minuteand 0 to 9,000 psi in order to optimally fill the annular region betweenthe tubular member 1110 and the tubular liner 1008 with fluidicmaterials. In a preferred embodiment, the fluid passages 1140 include aninlet geometry that can receive a dart and/or a ball sealing member. Inthis manner, the fluid passages 1140 can be sealed off by introducing aplug, dart and/or ball sealing elements into the fluid passage 1130. Ina preferred embodiment, the apparatus 1100 includes a plurality of fluidpassage 1140.

[0297] In an alternative embodiment, the base of the shoe 1115 includesa single inlet passage coupled to the fluid passages 1140 that isadapted to receive a plug, or other similar device, to permit theinterior region of the tubular member 1110 to be fluidicly isolated fromthe exterior of the tubular member 1110.

[0298] The seals 1145 are coupled to and supported by a lower endportion of the tubular member 1110. The seals 1145 are furtherpositioned on an outer surface of the lower end portion of the tubularmember 1110. The seals 1145 permit the overlapping joint between theupper end portion of the casing 1012 and the lower end portion of thetubular member 1110 to be fluidicly sealed.

[0299] The seals 1145 may comprise any number of conventionalcommercially available seals such as, for example, lead, rubber, Teflonor epoxy seals modified in accordance with the teachings of the presentdisclosure. In a preferred embodiment, the seals 1145 comprise sealsmolded from Stratalock epoxy available from Halliburton Energy Servicesin Dallas, Tex. in order to optimally provide a hydraulic seal in theoverlapping joint and optimally provide load carrying capacity towithstand the range of typical tensile and compressive loads.

[0300] In a preferred embodiment, the seals 1145 are selected tooptimally provide a sufficient frictional force to support the expandedtubular member 1110 from the tubular liner 1008. In a preferredembodiment, the frictional force provided by the seals 1145 ranges fromabout 1,000 to 1,000,000 lbf in tension and compression in order tooptimally support the expanded tubular member 1110.

[0301] The support member 1150 is coupled to the expandable mandrel1105, tubular member 1110, shoe 1115, and seal 1120. The support member1150 preferably comprises an annular member having sufficient strengthto carry the apparatus 1100 into the wellbore 1000. In a preferredembodiment, the support member 1150 further includes one or moreconventional centralizers (not illustrated) to help stabilize thetubular member 1110.

[0302] In a preferred embodiment, a quantity of lubricant 1150 isprovided in the annular region above the expandable mandrel 1105 withinthe interior of the tubular member 1110. In this manner, the extrusionof the tubular member 1110 off of the expandable mandrel 1105 isfacilitated. The lubricant 1150 may comprise any number of conventionalcommercially available lubricants such as, for example, Lubriplate,chlorine based lubricants or Climax 1500 Antiseize (3100). In apreferred embodiment, the lubricant 1150 comprises Climax 1500 Antiseize(3100) available from Climax Lubricants and Equipment Co. in Houston,Tex. in order to optimally provide lubrication for the extrusionprocess.

[0303] In a preferred embodiment, the support member 1150 is thoroughlycleaned prior to assembly to the remaining portions of the apparatus1100. In this manner, the introduction of foreign material into theapparatus 1100 is minimized. This minimizes the possibility of foreignmaterial clogging the various flow passages and valves of the apparatus1100 and to ensure that no foreign material interferes with theexpansion mandrel 1105 during the extrusion process.

[0304] In a particularly preferred embodiment, the apparatus 1100includes a packer 1155 coupled to the bottom section of the shoe 1115for fluidicly isolating the region of the wellbore 1000 below theapparatus 1100. In this manner, fluidic materials are prevented fromentering the region of the wellbore 1000 below the apparatus 1100. Thepacker 1155 may comprise any number of conventional commerciallyavailable packers such as, for example, EZ Drill Packer, EZ SV Packer ora drillable cement retainer. In a preferred embodiment, the packer 1155comprises an EZ Drill Packer available from Halliburton Energy Servicesin Dallas, Tex. In an alternative embodiment, a high gel strength pillmay be set below the tie-back in place of the packer 1155. In anotheralternative embodiment, the packer 1155 may be omitted.

[0305] In a preferred embodiment, before or after positioning theapparatus 1100 within the wellbore 1100, a couple of wellbore volumesare circulated in order to ensure that no foreign materials are locatedwithin the wellbore 1000 that might clog up the various flow passagesand valves of the apparatus 1100 and to ensure that no foreign materialinterferes with the operation of the expansion mandrel 1105.

[0306] As illustrated in FIG. 10c, a hardenable fluidic sealing material1160 is then pumped from a surface location into the fluid passage 1130.The material 1160 then passes from the fluid passage 1130 into theinterior region of the tubular member 1110 below the expandable mandrel1105. The material 1160 then passes from the interior region of thetubular member 1110 into the fluid passages 1140. The material 1160 thenexits the apparatus 1100 and fills the annular region between theexterior of the tubular member 1110 and the interior wall of the tubularliner 1008. Continued pumping of the material 1160 causes the material1160 to fill up at least a portion of the annular region.

[0307] The material 1160 may be pumped into the annular region atpressures and flow rates ranging, for example, from about 0 to 5,000 psiand 0 to 1,500 gallons/min, respectively. In a preferred embodiment, thematerial 1160 is pumped into the annular region at pressures and flowrates specifically designed for the casing sizes being run, the annularspaces being filled, the pumping equipment available, and the propertiesof the fluid being pumped. The optimum flow rates and pressures arepreferably calculated using conventional empirical methods.

[0308] The hardenable fluidic sealing material 1160 may comprise anynumber of conventional commercially available hardenable fluidic sealingmaterials such as, for example, slag mix, cement or epoxy. In apreferred embodiment, the hardenable fluidic sealing material 1160comprises blended cements specifically designed for well section beingtied-back, available from Halliburton Energy Services in Dallas, Tex. inorder to optimally provide proper support for the tubular member 1110while maintaining optimum flow characteristics so as to minimizeoperational difficulties during the displacement of cement in theannular region. The optimum blend of the blended cements are preferablydetermined using conventional empirical methods.

[0309] The annular region may be filled with the material 1160 insufficient quantities to ensure that, upon radial expansion of thetubular member 1110, the annular region will be filled with material1160.

[0310] As illustrated in FIG. 10d, once the annular region has beenadequately filled with material 1160, one or more plugs 1165, or othersimilar devices, preferably are introduced into the fluid passages 1140thereby fluidicly isolating the interior region of the tubular member1110 from the annular region external to the tubular member 1110. In apreferred embodiment, a non hardenable fluidic material 1161 is thenpumped into the interior region of the tubular member 1110 below themandrel 1105 causing the interior region to pressurize. In aparticularly preferred embodiment, the one or more plugs 1165, or othersimilar devices, are introduced into the fluid passage 1140 with theintroduction of the non hardenable fluidic material. In this manner, theamount of hardenable fluidic material within the interior of the tubularmember 1110 is minimized.

[0311] As illustrated in FIG. 10e, once the interior region becomessufficiently pressurized, the tubular member 1110 is extruded off of theexpandable mandrel 1105. During the extrusion process, the expandablemandrel 1105 is raised out of the expanded portion of the tubular member1110.

[0312] The plugs 1165 are preferably placed into the fluid passages 1140by introducing the plugs 1165 into the fluid passage 1130 at a surfacelocation in a conventional manner. The plugs 1165 may comprise anynumber of conventional commercially available devices from plugging afluid passage such as, for example, brass balls, plugs, rubber balls, ordarts modified in accordance with the teachings of the presentdisclosure.

[0313] In a preferred embodiment, the plugs 1165 comprise low densityrubber balls. In an alternative embodiment, for a shoe 1105 having acommon central inlet passage, the plugs 1165 comprise a single latchdown dart.

[0314] After placement of the plugs 1165 in the fluid passages 1140, thenon hardenable fluidic material 1161 is preferably pumped into theinterior region of the tubular member 1110 below the mandrel 1105 atpressures and flow rates ranging from approximately 500 to 9,000 psi and40 to 3,000 gallons/min.

[0315] In a preferred embodiment, after placement of the plugs 1165 inthe fluid passages 1140, the non hardenable fluidic material 1161 ispreferably pumped into the interior region of the tubular member 1110below the mandrel 1105 at pressures and flow rates ranging fromapproximately 1200 to 8500 psi and 40 to 1250 gallons/min in order tooptimally provide extrusion of typical tubulars.

[0316] For typical tubular members 1110, the extrusion of the tubularmember 1110 off of the expandable mandrel 1105 will begin when thepressure of the interior region of the tubular member 1110 below themandrel 1105 reaches, for example, approximately 1200 to 8500 psi. In apreferred embodiment, the extrusion of the tubular member 1110 off ofthe expandable mandrel 1105 begins when the pressure of the interiorregion of the tubular member 1110 below the mandrel 1105 reachesapproximately 1200 to 8500 psi.

[0317] During the extrusion process, the expandable mandrel 1105 may beraised out of the expanded portion of the tubular member 1110 at ratesranging, for example, from about 0 to 5 ft/sec. In a preferredembodiment, during the extrusion process, the expandable mandrel 1105 israised out of the expanded portion of the tubular member 1110 at ratesranging from about 0 to 2 ft/sec in order to optimally provide permitadjustment of operational parameters, and optimally ensure that theextrusion process will be completed before the material 1160 cures.

[0318] In a preferred embodiment, at least a portion 1180 of the tubularmember 1110 has an internal diameter less than the outside diameter ofthe mandrel 1105. In this manner, when the mandrel 1105 expands thesection 1180 of the tubular member 1110, at least a portion of theexpanded section 1180 effects a seal with at least the wellbore casing1012. In a particularly preferred embodiment, the seal is effected bycompressing the seals 1016 between the expanded section 1180 and thewellbore casing 1012. In a preferred embodiment, the contact pressure ofthe joint between the expanded section 1180 of the tubular member 1110and the casing 1012 ranges from about 500 to 10,000 psi in order tooptimally provide pressure to activate the sealing members 1145 andprovide optimal resistance to ensure that the joint will withstandtypical extremes of tensile and compressive loads.

[0319] In an alternative preferred embodiment, substantially all of theentire length of the tubular member 1110 has an internal diameter lessthan the outside diameter of the mandrel 1105. In this manner, extrusionof the tubular member 1110 by the mandrel 1105 results in contactbetween substantially all of the expanded tubular member 1110 and theexisting casing 1008. In a preferred embodiment, the contact pressure ofthe joint between the expanded tubular member 1110 and the casings 1008and 1012 ranges from about 500 to 10,000 psi in order to optimallyprovide pressure to activate the sealing members 1145 and provideoptimal resistance to ensure that the joint will withstand typicalextremes of tensile and compressive loads.

[0320] In a preferred embodiment, the operating pressure and flow rateof the material 1161 is controllably ramped down when the expandablemandrel 1105 reaches the upper end portion of the tubular member 1110.In this manner, the sudden release of pressure caused by the completeextrusion of the tubular member 1110 off of the expandable mandrel 1105can be minimized. In a preferred embodiment, the operating pressure ofthe fluidic material 1161 is reduced in a substantially linear fashionfrom 100% to about 10% during the end of the extrusion process beginningwhen the mandrel 1105 has completed approximately all but about 5 feetof the extrusion process.

[0321] Alternatively, or in combination, a shock absorber is provided inthe support member 1150 in order to absorb the shock caused by thesudden release of pressure.

[0322] Alternatively, or in combination, a mandrel catching structure isprovided in the upper end portion of the tubular member 1110 in order tocatch or at least decelerate the mandrel 1105.

[0323] Referring to FIG. 10f, once the extrusion process is completed,the expandable mandrel 1105 is removed from the wellbore 1000. In apreferred embodiment, either before or after the removal of theexpandable mandrel 1105, the integrity of the fluidic seal of the jointbetween the upper portion of the tubular member 1110 and the upperportion of the tubular liner 1108 is tested using conventional methods.If the fluidic seal of the joint between the upper portion of thetubular member 1110 and the upper portion of the tubular liner 1008 issatisfactory, then the uncured portion of the material 1160 within theexpanded tubular member 1110 is then removed in a conventional manner.The material 1160 within the annular region between the tubular member1110 and the tubular liner 1008 is then allowed to cure.

[0324] As illustrated in FIG. 10f, preferably any remaining curedmaterial 1160 within the interior of the expanded tubular member 1110 isthen removed in a conventional manner using a conventional drill string.The resulting tie-back liner of casing 1170 includes the expandedtubular member 1110 and an outer annular layer 1175 of cured material1160.

[0325] As illustrated in FIG. 10g, the remaining bottom portion of theapparatus 1100 comprising the shoe 1115 and packer 1155 is thenpreferably removed by drilling out the shoe 1115 and packer 1155 usingconventional drilling methods.

[0326] In a particularly preferred embodiment, the apparatus 1100incorporates the apparatus 900.

[0327] Referring now to FIGS. 11a-11 f, an embodiment of an apparatusand method for hanging a tubular liner off of an existing wellborecasing will now be described. As illustrated in FIG. 11a, a wellbore1200 is positioned in a subterranean formation 1205. The wellbore 1200includes an existing cased section 1210 having a tubular casing 1215 andan annular outer layer of cement 1220.

[0328] In order to extend the wellbore 1200 into the subterraneanformation 1205, a drill string 1225 is used in a well known manner todrill out material from the subterranean formation 1205 to form a newsection 1230.

[0329] As illustrated in FIG. 11b, an apparatus 1300 for forming awellbore casing in a subterranean formation is then positioned in thenew section 1230 of the wellbore 100. The apparatus 1300 preferablyincludes an expandable mandrel or pig 1305, a tubular member 1310, ashoe 1315, a fluid passage 1320, a fluid passage 1330, a fluid passage1335, seals 1340, a support member 1345, and a wiper plug 1350.

[0330] The expandable mandrel 1305 is coupled to and supported by thesupport member 1345. The expandable mandrel 1305 is preferably adaptedto controllably expand in a radial direction. The expandable mandrel1305 may comprise any number of conventional commercially availableexpandable mandrels modified in accordance with the teachings of thepresent disclosure. In a preferred embodiment, the expandable mandrel1305 comprises a hydraulic expansion tool substantially as disclosed inU.S. Pat. No. 5,348,095, the disclosure of which is incorporated hereinby reference, modified in accordance with the teachings of the presentdisclosure.

[0331] The tubular member 1310 is coupled to and supported by theexpandable mandrel 1305. The tubular member 1310 is preferably expandedin the radial direction and extruded off of the expandable mandrel 1305.The tubular member 1310 may be fabricated from any number of materialssuch as, for example, Oilfield Country Tubular Goods (OCTG), 13 chromiumsteel tubing/casing or plastic casing. In a preferred embodiment, thetubular member 1310 is fabricated from OCTG. The inner and outerdiameters of the tubular member 1310 may range, for example, fromapproximately 0.75 to 47 inches and 1.05 to 48 inches, respectively. Ina preferred embodiment, the inner and outer diameters of the tubularmember 1310 range from about 3 to 15.5 inches and 3.5 to 16 inches,respectively in order to optimally provide minimal telescoping effect inthe most commonly encountered wellbore sizes.

[0332] In a preferred embodiment, the tubular member 1310 includes anupper portion 1355, an intermediate portion 1360, and a lower portion1365. In a preferred embodiment, the wall thickness and outer diameterof the upper portion 1355 of the tubular member 1310 range from about{fraction (3/8)} to 1½ inches and 3½ to 16 inches, respectively. In apreferred embodiment, the wall thickness and outer diameter of theintermediate portion 1360 of the tubular member 1310 range from about0.625 to 0.75 inches and 3 to 19 inches, respectively. In a preferredembodiment, the wall thickness and outer diameter of the lower portion1365 of the tubular member 1310 range from about {fraction (3/8)} to 1.5inches and 3.5 to 16 inches, respectively.

[0333] In a particularly preferred embodiment, the outer diameter of thelower portion 1365 of the tubular member 1310 is significantly less thanthe outer diameters of the upper and intermediate portions, 1355 and1360, of the tubular member 1310 in order to optimize the formation of aconcentric and overlapping arrangement of wellbore casings. In thismanner, as will be described below with reference to FIGS. 12 and 13, awellhead system is optimally provided. In a preferred embodiment, theformation of a wellhead system does not include the use of a hardenablefluidic material.

[0334] In a particularly preferred embodiment, the wall thickness of theintermediate section 1360 of the tubular member 1310 is less than orequal to the wall thickness of the upper and lower sections, 1355 and1365, of the tubular member 1310 in order to optimally faciliate theinitiation of the extrusion process and optimally permit the placementof the apparatus in areas of the wellbore having tight clearances.

[0335] The tubular member 1310 preferably comprises a solid member. In apreferred embodiment, the upper end portion 1355 of the tubular member1310 is slotted, perforated, or otherwise modified to catch or slow downthe mandrel 1305 when it completes the extrusion of tubular member 1310.In a preferred embodiment, the length of the tubular member 1310 islimited to minimize the possibility of buckling. For typical tubularmember 1310 materials, the length of the tubular member 1310 ispreferably limited to between about 40 to 20,000 feet in length.

[0336] The shoe 1315 is coupled to the tubular member 1310. The shoe1315 preferably includes fluid passages 1330 and 1335. The shoe 1315 maycomprise any number of conventional commercially available shoes suchas, for example, Super Seal II float shoe, Super Seal II Down-Jet floatshoe or guide shoe with a sealing sleeve for a latch-down plug modifiedin accordance with the teachings of the present disclosure. In apreferred embodiment, the shoe 1315 comprises an aluminum down-jet guideshoe with a sealing sleeve for a latch-down plug available fromHalliburton Energy Services in Dallas, Tex., modified in accordance withthe teachings of the present disclosure, in order to optimally guide thetubular member 1310 into the wellbore 1200, optimally fluidicly isolatethe interior of the tubular member 1310, and optimally permit thecomplete drill out of the shoe 1315 upon the completion of the extrusionand cementing operations.

[0337] In a preferred embodiment, the shoe 1315 further includes one ormore side outlet ports in fluidic communication with the fluid passage1330. In this manner, the shoe 1315 preferably injects hardenablefluidic sealing material into the region outside the shoe 1315 andtubular member 1310. In a preferred embodiment, the shoe 1315 includesthe fluid passage 1330 having an inlet geometry that can receive afluidic sealing member. In this manner, the fluid passage 1330 can besealed off by introducing a plug, dart and/or ball sealing elements intothe fluid passage 1330.

[0338] The fluid passage 1320 permits fluidic materials to betransported to and from the interior region of the tubular member 1310below the expandable mandrel 1305. The fluid passage 1320 is coupled toand positioned within the support member 1345 and the expandable mandrel1305. The fluid passage 1320 preferably extends from a position adjacentto the surface to the bottom of the expandable mandrel 1305. The fluidpassage 1320 is preferably positioned along a centerline of theapparatus 1300. The fluid passage 1320 is preferably selected totransport materials such as cement, drilling mud, or epoxies at flowrates and pressures ranging from about 0 to 3,000 gallons/minute and 0to 9,000 psi in order to optimally provide sufficient operatingpressures to circulate fluids at operationally efficient rates.

[0339] The fluid passage 1330 permits fluidic materials to betransported to and from the region exterior to the tubular member 1310and shoe 1315. The fluid passage 1330 is coupled to and positionedwithin the shoe 1315 in fluidic communication with the interior region1370 of the tubular member 1310 below the expandable mandrel 1305. Thefluid passage 1330 preferably has a cross-sectional shape that permits aplug, or other similar device, to be placed in fluid passage 1330 tothereby block further passage of fluidic materials. In this manner, theinterior region 1370 of the tubular member 1310 below the expandablemandrel 1305 can be fluidicly isolated from the region exterior to thetubular member 1310. This permits the interior region 1370 of thetubular member 1310 below the expandable mandrel 1305 to be pressurized.The fluid passage 1330 is preferably positioned substantially along thecenterline of the apparatus 1300.

[0340] The fluid passage 1330 is preferably selected to convey materialssuch as cement, drilling mud or epoxies at flow rates and pressuresranging from about 0 to 3,000 gallons/minute and 0 to 9,000 psi in orderto optimally fill the annular region between the tubular member 1310 andthe new section 1230 of the wellbore 1200 with fluidic materials. In apreferred embodiment, the fluid passage 1330 includes an inlet geometrythat can receive a dart and/or a ball sealing member. In this manner,the fluid passage 1330 can be sealed off by introducing a plug, dartand/or ball sealing elements into the fluid passage 1320.

[0341] The fluid passage 1335 permits fluidic materials to betransported to and from the region exterior to the tubular member 1310and shoe 1315. The fluid passage 1335 is coupled to and positionedwithin the shoe 1315 in fluidic communication with the fluid passage1330. The fluid passage 1335 is preferably positioned substantiallyalong the centerline of the apparatus 1300. The fluid passage 1335 ispreferably selected to convey materials such as cement, drilling mud orepoxies at flow rates and pressures ranging from about 0 to 3,000gallons/minute and 0 to 9,000 psi in order to optimally fill the annularregion between the tubular member 1310 and the new section 1230 of thewellbore 1200 with fluidic materials.

[0342] The seals 1340 are coupled to and supported by the upper endportion 1355 of the tubular member 1310. The seals 1340 are furtherpositioned on an outer surface of the upper end portion 1355 of thetubular member 1310. The seals 1340 permit the overlapping joint betweenthe lower end portion of the casing 1215 and the upper portion 1355 ofthe tubular member 1310 to be fluidicly sealed. The seals 1340 maycomprise any number of conventional commercially available seals suchas, for example, lead, rubber, Teflon, or epoxy seals modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the seals 1340 comprise seals molded from Stratalock epoxyavailable from Halliburton Energy Services in Dallas, Tex. in order tooptimally provide a hydraulic seal in the annulus of the overlappingjoint while also creating optimal load bearing capability to withstandtypical tensile and compressive loads.

[0343] In a preferred embodiment, the seals 1340 are selected tooptimally provide a sufficient frictional force to support the expandedtubular member 1310 from the existing casing 1215. In a preferredembodiment, the frictional force provided by the seals 1340 ranges fromabout 1,000 to 1,000,000 lbf in order to optimally support the expandedtubular member 1310.

[0344] The support member 1345 is coupled to the expandable mandrel1305, tubular member 1310, shoe 1315, and seals 1340. The support member1345 preferably comprises an annular member having sufficient strengthto carry the apparatus 1300 into the new section 1230 of the wellbore1200. In a preferred embodiment, the support member 1345 furtherincludes one or more conventional centralizers (not illustrated) to helpstabilize the tubular member 1310.

[0345] In a preferred embodiment, the support member 1345 is thoroughlycleaned prior to assembly to the remaining portions of the apparatus1300. In this manner, the introduction of foreign material into theapparatus 1300 is minimized. This minimizes the possibility of foreignmaterial clogging the various flow passages and valves of the apparatus1300 and to ensure that no foreign material interferes with theexpansion process.

[0346] The wiper plug 1350 is coupled to the mandrel 1305 within theinterior region 1370 of the tubular member 1310. The wiper plug 1350includes a fluid passage 1375 that is coupled to the fluid passage 1320.The wiper plug 1350 may comprise one or more conventional commerciallyavailable wiper plugs such as, for example, Multiple Stage Cementerlatch-down plugs, Omega latch-down plugs or three-wiper latch-down plugmodified in accordance with the teachings of the present disclosure. Ina preferred embodiment, the wiper plug 1350 comprises a Multiple StageCementer latch-down plug available from Halliburton Energy Services inDallas, Tex. modified in a conventional manner for releasable attachmentto the expansion mandrel 1305.

[0347] In a preferred embodiment, before or after positioning theapparatus 1300 within the new section 1230 of the wellbore 1200, acouple of wellbore volumes are circulated in order to ensure that noforeign materials are located within the wellbore 1200 that might clogup the various flow passages and valves of the apparatus 1300 and toensure that no foreign material interferes with the extrusion process.

[0348] As illustrated in FIG. 11c, a hardenable fluidic sealing material1380 is then pumped from a surface location into the fluid passage 1320.The material 1380 then passes from the fluid passage 1320, through thefluid passage 1375, and into the interior region 1370 of the tubularmember 1310 below the expandable mandrel 1305. The material 1380 thenpasses from the interior region 1370 into the fluid passage 1330. Thematerial 1380 then exits the apparatus 1300 via the fluid passage 1335and fills the annular region 1390 between the exterior of the tubularmember 1310 and the interior wall of the new section 1230 of thewellbore 1200. Continued pumping of the material 1380 causes thematerial 1380 to fill up at least a portion of the annular region 1390.

[0349] The material 1380 may be pumped into the annular region 1390 atpressures and flow rates ranging, for example, from about 0 to 5000 psiand 0 to 1,500 gallons/min, respectively. In a preferred embodiment, thematerial 1380 is pumped into the annular region 1390 at pressures andflow rates ranging from about 0 to 5000 psi and 0 to 1,500 gallons/min,respectively, in order to optimally fill the annular region between thetubular member 1310 and the new section 1230 of the wellbore 1200 withthe hardenable fluidic sealing material 1380.

[0350] The hardenable fluidic sealing material 1380 may comprise anynumber of conventional commercially available hardenable fluidic sealingmaterials such as, for example, slag mix, cement or epoxy. In apreferred embodiment, the hardenable fluidic sealing material 1380comprises blended cements designed specifically for the well sectionbeing drilled and available from Halliburton Energy Services in order tooptimally provide support for the tubular member 1310 duringdisplacement of the material 1380 in the annular region 1390. Theoptimum blend of the cement is preferably determined using conventionalempirical methods.

[0351] The annular region 1390 preferably is filled with the material1380 in sufficient quantities to ensure that, upon radial expansion ofthe tubular member 1310, the annular region 1390 of the new section 1230of the wellbore 1200 will be filled with material 1380.

[0352] As illustrated in FIG. 11d, once the annular region 1390 has beenadequately filled with material 1380, a wiper dart 1395, or othersimilar device, is introduced into the fluid passage 1320. The wiperdart 1395 is preferably pumped through the fluid passage 1320 by a nonhardenable fluidic material 1381. The wiper dart 1395 then preferablyengages the wiper plug 1350.

[0353] As illustrated in FIG. 11e, in a preferred embodiment, engagementof the wiper dart 1395 with the wiper plug 1350 causes the wiper plug1350 to decouple from the mandrel 1305. The wiper dart 1395 and wiperplug 1350 then preferably will lodge in the fluid passage 1330, therebyblocking fluid flow through the fluid passage 1330, and fluidiclyisolating the interior region 1370 of the tubular member 1310 from theannular region 1390. In a preferred embodiment, the non hardenablefluidic material 1381 is then pumped into the interior region 1370causing the interior region 1370 to pressurize. Once the interior region1370 becomes sufficiently pressurized, the tubular member 1310 isextruded off of the expandable mandrel 1305. During the extrusionprocess, the expandable mandrel 1305 is raised out of the expandedportion of the tubular member 1310 by the support member 1345.

[0354] The wiper dart 1395 is preferably placed into the fluid passage1320 by introducing the wiper dart 1395 into the fluid passage 1320 at asurface location in a conventional manner. The wiper dart 1395 maycomprise any number of conventional commercially available devices fromplugging a fluid passage such as, for example, Multiple Stage Cementerlatch-down plugs, Omega latch-down plugs or three wiper latch-downplug/dart modified in accordance with the teachings of the presentdisclosure. In a preferred embodiment, the wiper dart 1395 comprises athree wiper latch-down plug modified to latch and seal in the MultipleStage Cementer latch down plug 1350. The three wiper latch-down plug isavailable from Halliburton Energy Services in Dallas, Tex.

[0355] After blocking the fluid passage 1330 using the wiper plug 1330and wiper dart 1395, the non hardenable fluidic material 1381 may bepumped into the interior region 1370 at pressures and flow ratesranging, for example, from approximately 0 to 5000 psi and 0 to 1,500gallons/min in order to optimally extrude the tubular member 1310 off ofthe mandrel 1305. In this manner, the amount of hardenable fluidicmaterial within the interior of the tubular member 1310 is minimized.

[0356] In a preferred embodiment, after blocking the fluid passage 1330,the non hardenable fluidic material 1381 is preferably pumped into theinterior region 1370 at pressures and flow rates ranging fromapproximately 500 to 9,000 psi and 40 to 3,000 gallons/min in order tooptimally provide operating pressures to maintain the expansion processat rates sufficient to permit adjustments to be made in operatingparameters during the extrusion process.

[0357] For typical tubular members 1310, the extrusion of the tubularmember 1310 off of the expandable mandrel 1305 will begin when thepressure of the interior region 1370 reaches, for example, approximately500 to 9,000 psi. In a preferred embodiment, the extrusion of thetubular member 1310 off of the expandable mandrel 1305 is a function ofthe tubular member diameter, wall thickness of the tubular member,geometry of the mandrel, the type of lubricant, the composition of theshoe and tubular member, and the yield strength of the tubular member.The optimum flow rate and operating pressures are preferably determinedusing conventional empirical methods.

[0358] During the extrusion process, the expandable mandrel 1305 may beraised out of the expanded portion of the tubular member 1310 at ratesranging, for example, from about 0 to 5 ft/sec. In a preferredembodiment, during the extrusion process, the expandable mandrel 1305may be raised out of the expanded portion of the tubular member 1310 atrates ranging from about 0 to 2 ft/sec in order to optimally provide anefficient process, optimally permit operator adjustment of operationparameters, and ensure optimal completion of the extrusion processbefore curing of the material 1380.

[0359] When the upper end portion 1355 of the tubular member 1310 isextruded off of the expandable mandrel 1305, the outer surface of theupper end portion 1355 of the tubular member 1310 will preferablycontact the interior surface of the lower end portion of the casing 1215to form an fluid tight overlapping joint. The contact pressure of theoverlapping joint may range, for example, from approximately 50 to20,000 psi. In a preferred embodiment, the contact pressure of theoverlapping joint ranges from approximately 400 to 10,000 psi in orderto optimally provide contact pressure sufficient to ensure annularsealing and provide enough resistance to withstand typical tensile andcompressive loads. In a particularly preferred embodiment, the sealingmembers 1340 will ensure an adequate fluidic and gaseous seal in theoverlapping joint.

[0360] In a preferred embodiment, the operating pressure and flow rateof the non hardenable fluidic material 1381 is controllably ramped downwhen the expandable mandrel 1305 reaches the upper end portion 1355 ofthe tubular member 1310. In this manner, the sudden release of pressurecaused by the complete extrusion of the tubular member 1310 off of theexpandable mandrel 1305 can be minimized. In a preferred embodiment, theoperating pressure is reduced in a substantially linear fashion from100% to about 10% during the end of the extrusion process beginning whenthe mandrel 1305 has completed approximately all but about 5 feet of theextrusion process.

[0361] Alternatively, or in combination, a shock absorber is provided inthe support member 1345 in order to absorb the shock caused by thesudden release of pressure.

[0362] Alternatively, or in combination, a mandrel catching structure isprovided in the upper end portion 1355 of the tubular member 1310 inorder to catch or at least decelerate the mandrel 1305.

[0363] Once the extrusion process is completed, the expandable mandrel1305 is removed from the wellbore 1200. In a preferred embodiment,either before or after the removal of the expandable mandrel 1305, theintegrity of the fluidic seal of the overlapping joint between the upperportion 1355 of the tubular member 1310 and the lower portion of thecasing 1215 is tested using conventional methods. If the fluidic seal ofthe overlapping joint between the upper portion 1355 of the tubularmember 1310 and the lower portion of the casing 1215 is satisfactory,then the uncured portion of the material 1380 within the expandedtubular member 1310 is then removed in a conventional manner. Thematerial 1380 within the annular region 1390 is then allowed to cure.

[0364] As illustrated in FIG. 11f, preferably any remaining curedmaterial 1380 within the interior of the expanded tubular member 1310 isthen removed in a conventional manner using a conventional drill string.The resulting new section of casing 1400 includes the expanded tubularmember 1310 and an outer annular layer 1405 of cured material 305. Thebottom portion of the apparatus 1300 comprising the shoe 1315 may thenbe removed by drilling out the shoe 1315 using conventional drillingmethods.

[0365] Referring now to FIGS. 12 and 13, a preferred embodiment of awellhead system 1500 formed using one or more of the apparatus andprocesses described above with reference to FIGS. 1-11 f will bedescribed. The wellhead system 1500 preferably includes a conventionalChristmas tree/drilling spool assembly 1505, a thick wall casing 1510,an annular body of cement 1515, an outer casing 1520, an annular body ofcement 1525, an intermediate casing 1530, and an inner casing 1535.

[0366] The Christmas tree/drilling spool assembly 1505 may comprise anynumber of conventional Christmas tree/drilling spool assemblies such as,for example, the SS-15 Subsea Wellhead System, Spool Tree SubseaProduction System or the Compact Wellhead System available fromsuppliers such as Dril-Quip, Cameron or Breda, modified in accordancewith the teachings of the present disclosure. The drilling spoolassembly 1505 is preferably operably coupled to the thick wall casing1510 and/or the outer casing 1520. The assembly 1505 may be coupled tothe thick wall casing 1510 and/or outer casing 1520, for example, bywelding, a threaded connection or made from single stock. In a preferredembodiment, the assembly 1505 is coupled to the thick wall casing 1510and/or outer casing 1520 by welding.

[0367] The thick wall casing 1510 is positioned in the upper end of awellbore 1540. In a preferred embodiment, at least a portion of thethick wall casing 1510 extends above the surface 1545 in order tooptimally provide easy access and attachment to the Christmastree/drilling spool assembly 1505. The thick wall casing 1510 ispreferably coupled to the Christmas tree/drilling spool assembly 1505,the annular body of cement 1515, and the outer casing 1520.

[0368] The thick wall casing 1510 may comprise any number ofconventional commercially available high strength wellbore casings suchas, for example, Oilfield Country Tubular Goods, titanium tubing orstainless steel tubing. In a preferred embodiment, the thick wall casing1510 comprises Oilfield Country Tubular Goods available from variousforeign and domestic steel mills. In a preferred embodiment, the thickwall casing 1510 has a yield strength of about 40,000 to 135,000 psi inorder to optimally provide maximum burst, collapse, and tensilestrengths. In a preferred embodiment, the thick wall casing 1510 has afailure strength in excess of about 5,000 to 20,000 psi in order tooptimally provide maximum operating capacity and resistance todegradation of capacity after being drilled through for an extended timeperiod.

[0369] The annular body of cement 1515 provides support for the thickwall casing 1510. The annular body of cement 1515 may be provided usingany number of conventional processes for forming an annular body ofcement in a wellbore. The annular body of cement 1515 may comprise anynumber of conventional cement mixtures.

[0370] The outer casing 1520 is coupled to the thick wall casing 1510.The outer casing 1520 may be fabricated from any number of conventionalcommercially available tubular members modified in accordance with theteachings of the present disclosure. In a preferred embodiment, theouter casing 1520 comprises any one of the expandable tubular membersdescribed above with reference to FIGS. 1-11 f.

[0371] In a preferred embodiment, the outer casing 1520 is coupled tothe thick wall casing 1510 by expanding the outer casing 1520 intocontact with at least a portion of the interior surface of the thickwall casing 1510 using any one of the embodiments of the processes andapparatus described above with reference to FIGS. 1-11 f. In analternative embodiment, substantially all of the overlap of the outercasing 1520 with the thick wall casing 1510 contacts with the interiorsurface of the thick wall casing 1510. The contact pressure of theinterface between the outer casing 1520 and the thick wall casing 1510may range, for example, from about 500 to 10,000 psi. In a preferredembodiment, the contact pressure between the outer casing 1520 and thethick wall casing 1510 ranges from about 500 to 10,000 psi in order tooptimally activate the pressure activated sealing members and to ensurethat the overlapping joint will optimally withstand typical extremes oftensile and compressive loads that are experienced during drilling andproduction operations.

[0372] As illustrated in FIG. 13, in a particularly preferredembodiment, the upper end of the outer casing 1520 includes one or moresealing members 1550 that provide a gaseous and fluidic seal between theexpanded outer casing 1520 and the interior wall of the thick wallcasing 1510. The sealing members 1550 may comprise any number ofconventional commercially available seals such as, for example, lead,plastic, rubber, Teflon or epoxy, modified in accordance with theteachings of the present disclosure. In a preferred embodiment, thesealing members 1550 comprise seals molded from StrataLock epoxyavailable from Halliburton Energy Services in order to optimally providean hydraulic seal and a load bearing interference fit between thetubular members. In a preferred embodiment, the contact pressure of theinterface between the thick wall casing 1510 and the outer casing 1520ranges from about 500 to 10,000 psi in order to optimally activate thesealing members 1550 and also optimally ensure that the joint willwithstand the typical operating extremes of tensile and compressiveloads during drilling and production operations.

[0373] In an alternative preferred embodiment, the outer casing 1520 andthe thick walled casing 1510 are combined in one unitary member.

[0374] The annular body of cement 1525 provides support for the outercasing 1520. In a preferred embodiment, the annular body of cement 1525is provided using any one of the embodiments of the apparatus andprocesses described above with reference to FIGS. 1-11 f.

[0375] The intermediate casing 1530 may be coupled to the outer casing1520 or the thick wall casing 1510. In a preferred embodiment, theintermediate casing 1530 is coupled to the thick wall casing 1510. Theintermediate casing 1530 may be fabricated from any number ofconventional commercially available tubular members modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the intermediate casing 1530 comprises any one of theexpandable tubular members described above with reference to FIGS. 1-11f.

[0376] In a preferred embodiment, the intermediate casing 1530 iscoupled to the thick wall casing 1510 by expanding at least a portion ofthe intermediate casing 1530 into contact with the interior surface ofthe thick wall casing 1510 using any one of the processes and apparatusdescribed above with reference to FIGS. 1-11 f. In an alternativepreferred embodiment, the entire length of the overlap of theintermediate casing 1530 with the thick wall casing 1510 contacts theinner surface of the thick wall casing 1510. The contact pressure of theinterface between the intermediate casing 1530 and the thick wall casing1510 may range, for example from about 500 to 10,000 psi. In a preferredembodiment, the contact pressure between the intermediate casing 1530and the thick wall casing 1510 ranges from about 500 to 10,000 psi inorder to optimally activate the pressure activated sealing members andto optimally ensure that the joint will withstand typical operatingextremes of tensile and compressive loads experienced during drillingand production operations.

[0377] As illustrated in FIG. 13, in a particularly preferredembodiment, the upper end of the intermediate casing 1530 includes oneor more sealing members 1560 that provide a gaseous and fluidic sealbetween the expanded end of the intermediate casing 1530 and theinterior wall of the thick wall casing 1510. The sealing members 1560may comprise any number of conventional commercially available sealssuch as, for example, plastic, lead, rubber, Teflon or epoxy, modifiedin accordance with the teachings of the present disclosure. In apreferred embodiment, the sealing members 1560 comprise seals moldedfrom StrataLock epoxy available from Halliburton Energy Services inorder to optimally provide a hydraulic seal and a load bearinginterference fit between the tubular members.

[0378] In a preferred embodiment, the contact pressure of the interfacebetween the expanded end of the intermediate casing 1530 and the thickwall casing 1510 ranges from about 500 to 10,000 psi in order tooptimally activate the sealing members 1560 and also optimally ensurethat the joint will withstand typical operating extremes of tensile andcompressive loads that are experienced during drilling and productionoperations.

[0379] The inner casing 1535 may be coupled to the outer casing 1520 orthe thick wall casing 1510. In a preferred embodiment, the inner casing1535 is coupled to the thick wall casing 1510. The inner casing 1535 maybe fabricated from any number of conventional commercially availabletubular members modified in accordance with the teachings of the presentdisclosure. In a preferred embodiment, the inner casing 1535 comprisesany one of the expandable tubular members described above with referenceto FIGS. 1-11 f.

[0380] In a preferred embodiment, the inner casing 1535 is coupled tothe outer casing 1520 by expanding at least a portion of the innercasing 1535 into contact with the interior surface of the thick wallcasing 1510 using any one of the processes and apparatus described abovewith reference to FIGS. 1-11 f. In an alternative preferred embodiment,the entire length of the overlap of the inner casing 1535 with the thickwall casing 1510 and intermediate casing 1530 contacts the innersurfaces of the thick wall casing 1510 and intermediate casing 1530. Thecontact pressure of the interface between the inner casing 1535 and thethick wall casing 1510 may range, for example from about 500 to 10,000psi. In a preferred embodiment, the contact pressure between the innercasing 1535 and the thick wall casing 1510 ranges from about 500 to10,000 psi in order to optimally activate the pressure activated sealingmembers and to ensure that the joint will withstand typical extremes oftensile and compressive loads that are commonly experienced duringdrilling and production operations.

[0381] As illustrated in FIG. 13, in a particularly preferredembodiment, the upper end of the inner casing 1535 includes one or moresealing members 1570 that provide a gaseous and fluidic seal between theexpanded end of the inner casing 1535 and the interior wall of the thickwall casing 1510. The sealing members 1570 may comprise any number ofconventional commercially available seals such as, for example, lead,plastic, rubber, Teflon or epoxy, modified in accordance with theteachings of the present disclosure. In a preferred embodiment, thesealing members 1570 comprise seals molded from StrataLock epoxyavailable from Halliburton Energy Services in order to optimally providean hydraulic seal and a load bearing interference fit. In a preferredembodiment, the contact pressure of the interface between the expandedend of the inner casing 1535 and the thick wall casing 1510 ranges fromabout 500 to 10,000 psi in order to optimally activate the sealingmembers 1570 and also to optimally ensure that the joint will withstandtypical operating extremes of tensile and compressive loads that areexperienced during drilling and production operations.

[0382] In an alternative embodiment, the inner casings, 1520, 1530 and1535, may be coupled to a previously positioned tubular member that isin turn coupled to the outer casing 1510. More generally, the presentpreferred embodiments may be used to form a concentric arrangement oftubular members.

[0383] Referring now to FIGS. 14a, 14 b, 14 c, 14 d, 14 e and 14 f, apreferred embodiment of a method and apparatus for forming amono-diameter well casing within a subterranean formation will now bedescribed.

[0384] As illustrated in FIG. 14a, a wellbore 1600 is positioned in asubterranean formation 1605. A first section of casing 1610 is formed inthe wellbore 1600. The first section of casing 1610 includes an annularouter body of cement 1615 and a tubular section of casing 1620. Thefirst section of casing 1610 may be formed in the wellbore 1600 usingconventional methods and apparatus. In a preferred embodiment, the firstsection of casing 1610 is formed using one or more of the methods andapparatus described above with reference to FIGS. 1-13 or below withreference to FIGS. 14b-17 b.

[0385] The annular body of cement 1615 may comprise any number ofconventional commercially available cement, or other load bearing,compositions. Alternatively, the body of cement 1615 may be omitted orreplaced with an epoxy mixture.

[0386] The tubular section of casing 1620 preferably includes an upperend 1625 and a lower end 1630. Preferably, the lower end 1625 of thetubular section of casing 1620 includes an outer annular recess 1635extending from the lower end 1630 of the tubular section of casing 1620.In this manner, the lower end 1625 of the tubular section of casing 1620includes a thin walled section 1640. In a preferred embodiment, anannular body 1645 of a compressible material is coupled to and at leastpartially positioned within the outer annular recess 1635. In thismanner, the body of compressible material 1645 surrounds at least aportion of the thin walled section 1640.

[0387] The tubular section of casing 1620 may be fabricated from anynumber of conventional commercially available materials such as, forexample, oilfield country tubular goods, stainless steel, automotivegrade steel, carbon steel, low alloy steel, fiberglass or plastics. In apreferred embodiment, the tubular section of casing 1620 is fabricatedfrom oilfield country tubular goods available from various foreign anddomestic steel mills. The wall thickness of the thin walled section 1640may range from about 0.125 to 1.5 inches. In a preferred embodiment, thewall thickness of the thin walled section 1640 ranges from 0.25 to 1.0inches in order to optimally provide burst strength for typicaloperational conditions while also minimizing resistance to radialexpansion. The axial length of the thin walled section 1640 may rangefrom about 120 to 2400 inches. In a preferred embodiment, the axiallength of the thin walled section 1640 ranges from about 240 to 480inches.

[0388] The annular body of compressible material 1645 helps to minimizethe radial force required to expand the tubular casing 1620 in theoverlap with the tubular member 1715, helps to create a fluidic seal inthe overlap with the tubular member 1715, and helps to create aninterference fit sufficient to permit the tubular member 1715 to besupported by the tubular casing 1620. The annular body of compressiblematerial 1645 may comprise any number of commercially availablecompressible materials such as, for example, epoxy, rubber, Teflon,plastics or lead tubes. In a preferred embodiment, the annular body ofcompressible material 1645 comprises StrataLock epoxy available fromHalliburton Energy Services in order to optimally provide an hydraulicseal in the overlapped joint while also having compliance to therebyminimize the radial force required to expand the tubular casing. Thewall thickness of the annular body of compressible material 1645 mayrange from about 0.05 to 0.75 inches. In a preferred embodiment, thewall thickness of the annular body of compressible material 1645 rangesfrom about 0.1 to 0.5 inches in order to optimally provide a largecompressible zone, minimize the radial forces required to expand thetubular casing, provide thickness for casing strings to provide contactwith the inner surface of the wellbore upon radial expansion, andprovide an hydraulic seal.

[0389] As illustrated in FIG. 14b, in order to extend the wellbore 1600into the subterranean formation 1605, a drill string is used in a wellknown manner to drill out material from the subterranean formation 1605to form a new wellbore section 1650. The diameter of the new section1650 is preferably equal to or greater than the inner diameter of thetubular section of casing 1620.

[0390] As illustrated in FIG. 14c, a preferred embodiment of anapparatus 1700 for forming a mono-diameter wellbore casing in asubterranean formation is then positioned in the new section 1650 of thewellbore 1600. The apparatus 1700 preferably includes a support member1705, an expandable mandrel or pig 1710, a tubular member 1715, a shoe1720, slips 1725, a fluid passage 1730, one or more fluid passages 1735,a fluid passage 1740, a first compressible annular body 1745, a secondcompressible annular body 1750, and a pressure chamber 1755.

[0391] The support member 1705 supports the apparatus 1700 within thewellbore 1600. The support member 1705 is coupled to the mandrel 1710,the tubular member 1715, the shoe 1720, and the slips 1725. The supportmember 1075 preferably comprises a substantially hollow tubular member.The fluid passage 1730 is positioned within the support member 1705. Thefluid passages 1735 fluidicly couple the fluid passage 1730 with thepressure chamber 1755. The fluid passage 1740 fluidicly couples thefluid passage 1730 with the region outside of the apparatus 1700.

[0392] The support member 1705 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, stainless steel, low alloy steel, carbonsteel, 13 chromium steel, fiberglass, or other high strength materials.In a preferred embodiment, the support member 1705 is fabricated fromoilfield country tubular goods available from various foreign anddomestic steel mills in order to optimally provide operational strengthand faciliate the use of other standard oil exploration handlingequipment. In a preferred embodiment, at least a portion of the supportmember 1705 comprises coiled tubing or a drill pipe. In a particularlypreferred embodiment, the support member 1705 includes a load shoulder1820 for supporting the mandrel 1710 when the pressure chamber 1755 isunpressurized.

[0393] The mandrel 1710 is supported by and slidingly coupled to thesupport member 1705 and the shoe 1720. The mandrel 1710 preferablyincludes an upper portion 1760 and a lower portion 1765. Preferably, theupper portion 1760 of the mandrel 1710 and the support member 1705together define the pressure chamber 1755. Preferably, the lower portion1765 of the mandrel 1710 includes an expansion member 1770 for radiallyexpanding the tubular member 1715.

[0394] In a preferred embodiment, the upper portion 1760 of the mandrel1710 includes a tubular member 1775 having an inner diameter greaterthan an outer diameter of the support member 1705. In this manner, anannular pressure chamber 1755 is defined by and positioned between thetubular member 1775 and the support member 1705. The top 1780 of thetubular member 1775 preferably includes a bearing and a seal for sealingand supporting the top 1780 of the tubular member 1775 against the outersurface of the support member 1705. The bottom 1785 of the tubularmember 1775 preferably includes a bearing and seal for sealing andsupporting the bottom 1785 of the tubular member 1775 against the outersurface of the support member 1705 or shoe 1720. In this manner, themandrel 1710 moves in an axial direction upon the pressurization of thepressure chamber 1755.

[0395] The lower portion 1765 of the mandrel 1710 preferably includes anexpansion member 1770 for radially expanding the tubular member 1715during the pressurization of the pressure chamber 1755. In a preferredembodiment, the expansion member is expandable in the radial direction.In a preferred embodiment, the inner surface of the lower portion 1765of the mandrel 1710 mates with and slides with respect to the outersurface of the shoe 1720. The outer diameter of the expansion member1770 may range from about 90 to 100% of the inner diameter of thetubular casing 1620. In a preferred embodiment, the outer diameter ofthe expansion member 1770 ranges from about 95 to 99% of the innerdiameter of the tubular casing 1620. The expansion member 1770 may befabricated from any number of conventional commercially availablematerials such as, for example, machine tool steel, ceramics, tungstencarbide, titanium or other high strength alloys. In a preferredembodiment, the expansion member 1770 is fabricated from D2 machine toolsteel in order to optimally provide high strength and abrasionresistance.

[0396] The tubular member 1715 is coupled to and supported by thesupport member 1705 and slips 1725. The tubular member 1715 includes anupper portion 1790 and a lower portion 1795.

[0397] The upper portion 1790 of the tubular member 1715 preferablyincludes an inner annular recess 1800 that extends from the upperportion 1790 of the tubular member 1715. In this manner, at least aportion of the upper portion 1790 of the tubular member 1715 includes athin walled section 1805. The first compressible annular member 1745 ispreferably coupled to and supported by the outer surface of the upperportion 1790 of the tubular member 1715 in opposing relation to the thinwall section 1805.

[0398] The lower portion 1795 of the tubular member 1715 preferablyincludes an outer annular recess 1810 that extends from the lowerportion 1790 of the tubular member 1715. In this manner, at least aportion of the lower portion 1795 of the tubular member 1715 includes athin walled section 1815. The second compressible annular member 1750 iscoupled to and at least partially supported within the outer annularrecess 1810 of the upper portion 1790 of the tubular member 1715 inopposing relation to the thin wall section 1815.

[0399] The tubular member 1715 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, stainless steel, low alloy steel, carbonsteel, automotive grade steel, fiberglass, 13 chrome steel, other highstrength material, or high strength plastics. In a preferred embodiment,the tubular member 1715 is fabricated from oilfield country tubulargoods available from various foreign and domestic steel mills in orderto optimally provide operational strength.

[0400] The shoe 1720 is supported by and coupled to the support member1705. The shoe 1720 preferably comprises a substantially hollow tubularmember. In a preferred embodiment, the wall thickness of the shoe 1720is greater than the wall thickness of the support member 1705 in orderto optimally provide increased radial support to the mandrel 1710. Theshoe 1720 may be fabricated from any number of conventional commerciallyavailable materials such as, for example, oilfield country tubulargoods, stainless steel, automotive grade steel, low alloy steel, carbonsteel, or high strength plastics. In a preferred embodiment, the shoe1720 is fabricated from oilfield country tubular goods available fromvarious foreign and domestic steel mills in order to optimally providematching operational strength throughout the apparatus.

[0401] The slips 1725 are coupled to and supported by the support member1705. The slips 1725 removably support the tubular member 1715. In thismanner, during the radial expansion of the tubular member 1715, theslips 1725 help to maintain the tubular member 1715 in a substantiallystationary position by preventing upward movement of the tubular member1715.

[0402] The slips 1725 may comprise any number of conventionalcommercially available slips such as, for example, RTTS packer tungstencarbide mechanical slips, RTTS packer wicker type mechanical slips, orModel 3L retrievable bridge plug tungsten carbide upper mechanicalslips. In a preferred embodiment, the slips 1725 comprise RTTS packertungsten carbide mechanical slips available from Halliburton EnergyServices. In a preferred embodiment, the slips 1725 are adapted tosupport axial forces ranging from about 0 to 750,000 lbf.

[0403] The fluid passage 1730 conveys fluidic materials from a surfacelocation into the interior of the support member 1705, the pressurechamber 1755, and the region exterior of the apparatus 1700. The fluidpassage 1730 is fludicly coupled to the pressure chamber 1755 by thefluid passages 1735. The fluid passage 1730 is fluidicly coupled to theregion exterior to the apparatus 1700 by the fluid passage 1740.

[0404] In a preferred embodiment, the fluid passage 1730 is adapted toconvey fluidic materials such as, for example, cement, epoxy, drillingmuds, slag mix, water or drilling gasses. In a preferred embodiment, thefluid passage 1730 is adapted to convey fluidic materials at flow rateand pressures ranging from about 0 to 3,000 gallons/minute and 0 to9,000 psi. in order to optimally provide flow rates and operationalpressures for the radial expansion processes.

[0405] The fluid passages 1735 convey fluidic material from the fluidpassage 1730 to the pressure chamber 1755. In a preferred embodiment,the fluid passage 1735 is adapted to convey fluidic materials such as,for example, cement, epoxy, drilling muds, water or drilling gasses. Ina preferred embodiment, the fluid passage 1735 is adapted to conveyfluidic materials at flow rate and pressures ranging from about 0 to 500gallons/minute and 0 to 9,000 psi. in order to optimally provideoperating pressures and flow rates for the various expansion processes.

[0406] The fluid passage 1740 conveys fluidic materials from the fluidpassage 1730 to the region exterior to the apparatus 1700. In apreferred embodiment, the fluid passage 1740 is adapted to conveyfluidic materials such as, for example, cement, epoxy, drilling muds,water or drilling gasses. In a preferred embodiment, the fluid passage1740 is adapted to convey fluidic materials at flow rate and pressuresranging from about 0 to 3,000 gallons/minute and 0 to 9,000 psi. inorder to optimally provide operating pressures and flow rates for thevarious radial expansion processes.

[0407] In a preferred embodiment, the fluid passage 1740 is adapted toreceive a plug or other similar device for sealing the fluid passage1740. In this manner, the pressure chamber 1755 may be pressurized.

[0408] The first compressible annular body 1745 is coupled to andsupported by an exterior surface of the upper portion 1790 of thetubular member 1715. In a preferred embodiment, the first compressibleannular body 1745 is positioned in opposing relation to the thin walledsection 1805 of the tubular member 1715.

[0409] The first compressible annular body 1745 helps to minimize theradial force required to expand the tubular member 1715 in the overlapwith the tubular casing 1620, helps to create a fluidic seal in theoverlap with the tubular casing 1620, and helps to create aninterference fit sufficient to permit the tubular member 1715 to besupported by the tubular casing 1620. The first compressible annularbody 1745 may comprise any number of commercially available compressiblematerials such as, for example, epoxy, rubber, Teflon, plastics, orhollow lead tubes. In a preferred embodiment, the first compressibleannular body 1745 comprises StrataLock epoxy available from HalliburtonEnergy Services in order to optimally provide an hydraulic seal, andcompressibility to minimize the radial expansion force.

[0410] The wall thickness of the first compressible annular body 1745may range from about 0.05 to 0.75 inches. In a preferred embodiment, thewall thickness of the first compressible annular body 1745 ranges fromabout 0.1 to 0.5 inches in order to optimally (1) provide a largecompressible zone, (2) minimize the required radial expansion force, (3)transfer the radial force to the tubular casings. As a result, in apreferred embodiment, overall the outer diameter of the tubular member1715 is approximately equal to the overall inner diameter of the tubularmember 1620.

[0411] The second compressible annular body 1750 is coupled to and atleast partially supported within the outer annular recess 1810 of thetubular member 1715. In a preferred embodiment, the second compressibleannular body 1750 is positioned in opposing relation to the thin walledsection 1815 of the tubular member 1715.

[0412] The second compressible annular body 1750 helps to minimize theradial force required to expand the tubular member 1715 in the overlapwith another tubular member, helps to create a fluidic seal in theoverlap of the tubular member 1715 with another tubular member, andhelps to create an interference fit sufficient to permit another tubularmember to be supported by the tubular member 1715. The secondcompressible annular body 1750 may comprise any number of commerciallyavailable compressible materials such as, for example, epoxy, rubber,Teflon, plastics or hollow lead tubing. In a preferred embodiment, thefirst compressible annular body 1750 comprises StrataLock epoxyavailable from Halliburton Energy Services in order to optimally providean hydraulic seal in the overlapped joint, and compressibility thatminimizes the radial expansion force.

[0413] The wall thickness of the second compressible annular body 1750may range from about 0.05 to 0.75 inches. In a preferred embodiment, thewall thickness of the second compressible annular body 1750 ranges fromabout 0.1 to 0.5 inches in order to optimally provide a largecompressible zone, and minimize the radial force required to expand thetubular member 1715 during subsequent radial expansion operations.

[0414] In an alternative embodiment, the outside diameter of the secondcompressible annular body 1750 is adapted to provide a seal against thesurrounding formation thereby eliminating the need for an outer annularbody of cement.

[0415] The pressure chamber 1755 is fludicly coupled to the fluidpassage 1730 by the fluid passages 1735. The pressure chamber 1755 ispreferably adapted to receive fluidic materials such as, for example,drilling muds, water or drilling gases. In a preferred embodiment, thepressure chamber 1755 is adapted to receive fluidic materials at flowrate and pressures ranging from about 0 to 500 gallons/minute and 0 to9,000 psi. in order to optimally provide expansion pressure. In apreferred embodiment, during pressurization of the pressure chamber1755, the operating pressure of the pressure chamber ranges from about 0to 5,000 psi in order to optimally provide expansion pressure whileminimizing the possibility of a catastrophic failure due to overpressurization.

[0416] As illustrated in FIG. 14d, the apparatus 1700 is preferablypositioned in the wellbore 1600 with the tubular member 1715 positionedin an overlapping relationship with the tubular casing 1620. In aparticularly preferred embodiment, the thin wall sections, 1640 and1805, of the tubular casing 1620 and tubular member 1725 are positionedin opposing overlapping relation. In this manner, the radial expansionof the tubular member 1725 will compress the thin wall sections, 1640and 1805, and annular compressible members, 1645 and 1745, into intimatecontact.

[0417] After positioning of the apparatus 1700, a fluidic material 1825is then pumped into the fluid passage 1730. The fluidic material 1825may comprise any number of conventional commercially available materialssuch as, for example, water, drilling mud, drilling gases, cement orepoxy. In a preferred embodiment, the fluidic material 1825 comprises ahardenable fluidic sealing material such as, for example, cement inorder to provide an outer annular body around the expanded tubularmember 1715.

[0418] The fluidic material 1825 may be pumped into the fluid passage1730 at operating pressures and flow rates, for example, ranging fromabout 0 to 9,000 psi and 0 to 3,000 gallons/minute.

[0419] The fluidic material 1825 pumped into the fluid passage 1730passes through the fluid passage 1740 and outside of the apparatus 1700.The fluidic material 1825 fills the annular region 1830 between theoutside of the apparatus 1700 and the interior walls of the wellbore1600.

[0420] As illustrated in FIG. 14e, a plug 1835 is then introduced intothe fluid passage 1730. The plug 1835 lodges in the inlet to the fluidpassage 1740 fluidicly isolating and blocking off the fluid passage1730.

[0421] A fluidic material 1840 is then pumped into the fluid passage1730. The fluidic material 1840 may comprise any number of conventionalcommercially available materials such as, for example, water, drillingmud or drilling gases. In a preferred embodiment, the fluidic material1825 comprises a non-hardenable fluidic material such as, for example,drilling mud or drilling gases in order to optimally providepressurization of the pressure chamber 1755.

[0422] The fluidic material 1840 may be pumped into the fluid passage1730 at operating pressures and flow rates ranging, for example, fromabout 0 to 9,000 psi and 0 to 500 gallons/minute. In a preferredembodiment, the fluidic material 1840 is pumped into the fluid passage1730 at operating pressures and flow rates ranging from about 500 to5,000 psi and 0 to 500 gallons/minute in order to optimally provideoperating pressures and flow rates for radial expansion.

[0423] The fluidic material 1840 pumped into the fluid passage 1730passes through the fluid passages 1735 and into the pressure chamber1755. Continued pumping of the fluidic material 1840 pressurizes thepressure chamber 1755. The pressurization of the pressure chamber 1755causes the mandrel 1710 to move relative to the support member 1705 inthe direction indicated by the arrows 1845. In this manner, the mandrel1710 will cause the tubular member 1715 to expand in the radialdirection.

[0424] During the radial expansion process, the tubular member 1715 isprevented from moving in an upward direction by the slips 1725. A lengthof the tubular member 1715 is then expanded in the radial directionthrough the pressurization of the pressure chamber 1755. The length ofthe tubular member 1715 that is expanded during the expansion processwill be proportional to the stroke length of the mandrel 1710. Upon thecompletion of a stroke, the operating pressure of the pressure chamber1755 is then reduced and the mandrel 1710 drops to it rest position withthe tubular member 1715 supported by the mandrel 1715. The position ofthe support member 1705 may be adjusted throughout the radial expansionprocess in order to maintain the overlapping relationship between thethin walled sections, 1640 and 1805, of the tubular casing 1620 andtubular member 1715. The stroking of the mandrel 1710 is then repeated,as necessary, until the thin walled section 1805 of the tubular member1715 is expanded into the thin walled section 1640 of the tubular casing1620.

[0425] In a preferred embodiment, during the final stroke of the mandrel1710, the slips 1725 are positioned as close as possible to the thinwalled section 1805 of the tubular member 1715 in order minimizeslippage between the tubular member 1715 and tubular casing 1620 at theend of the radial expansion process. Alternatively, or in addition, theoutside diameter of the first compressive annular member 1745 isselected to ensure sufficient interference fit with the tubular casing1620 to prevent axial displacement of the tubular member 1715 during thefinal stroke. Alternatively, or in addition, the outside diameter of thesecond compressive annular body 1750 is large enough to provide aninterference fit with the inside walls of the wellbore 1600 at anearlier point in the radial expansion process so as to prevent furtheraxial displacement of the tubular member 1715. In this finalalternative, the interference fit is preferably selected to permitexpansion of the tubular member 1715 by pulling the mandrel 1710 out ofthe wellbore 1600, without having to pressurize the pressure chamber1755.

[0426] During the radial expansion process, the pressurized areas of theapparatus 1700 are limited to the fluid passages 1730 within the supportmember 1705 and the pressure chamber 1755 within the mandrel 1710. Nofluid pressure acts directly on the tubular member 1715. This permitsthe use of operating pressures higher than the tubular member 1715 couldnormally withstand.

[0427] Once the tubular member 1715 has been completely expanded off ofthe mandrel 1710, the support member 1705 and mandrel 1710 are removedfrom the wellbore 1600. In a preferred embodiment, the contact pressurebetween the deformed thin wall sections, 1640 and 1805, and compressibleannular members, 1645 and 1745, ranges from about 400 to 10,000 psi inorder to optimally support the tubular member 1715 using the tubularcasing 1620.

[0428] In this manner, the tubular member 1715 is radially expanded intocontact with the tubular casing 1620 by pressurizing the interior of thefluid passage 1730 and the pressure chamber 1755.

[0429] As illustrated in FIG. 14f, in a preferred embodiment, once thetubular member 1715 is completely expanded in the radial direction bythe mandrel 1710, the support member 1705 and mandrel 1710 are removedfrom the wellbore 1600. In a preferred embodiment, the annular body ofhardenable fluidic material is then allowed to cure to form a rigidouter annular body 1850. In the case where the tubular member 1715 isslotted, the hardenable fluidic material will preferably permeate andenvelop the expanded tubular member 1715.

[0430] The resulting new section of wellbore casing 1855 includes theexpanded tubular member 1715 and the rigid outer annular body 1850. Theoverlapping joint 1860 between the tubular casing 1620 and the expandedtubular member 1715 includes the deformed thin wall sections, 1640 and1805, and the compressible annular bodies, 1645 and 1745. The innerdiameter of the resulting combined wellbore casings is substantiallyconstant. In this manner, a mono-diameter wellbore casing is formed.This process of expanding overlapping tubular members having thin wallend portions with compressible annular bodies into contact can berepeated for the entire length of a wellbore. In this manner, amono-diameter wellbore casing can be provided for thousands of feet in asubterranean formation.

[0431] Referring now to FIGS. 15, 15a and 15 b, an embodiment of anapparatus 1900 for expanding a tubular member will be described. Theapparatus 1900 preferably includes a drillpipe 1905, an innerstringadapter 1910, a sealing sleeve 1915, an inner sealing mandrel 1920, anupper sealing head 1925, a lower sealing head 1930, an outer sealingmandrel 1935, a load mandrel 1940, an expansion cone 1945, a mandrellauncher 1950, a mechanical slip body 1955, mechanical slips 1960, dragblocks 1965, casing 1970, and fluid passages 1975, 1980, 1985, and 1990.

[0432] The drillpipe 1905 is coupled to the innerstring adapter 1910.During operation of the apparatus 1900, the drillpipe 1905 supports theapparatus 1900. The drillpipe 1905 preferably comprises a substantiallyhollow tubular member or members. The drillpipe 1905 may be fabricatedfrom any number of conventional commercially available materials suchas, for example, oilfield country tubular drillpipe, fiberglass orcoiled tubing. In a preferred embodiment, the drillpipe 1905 isfabricated from coiled tubing in order to faciliate the placement of theapparatus 1900 in non-vertical wellbores. The drillpipe 1905 may becoupled to the innerstring adapter 1910 using any number of conventionalcommercially available mechanical couplings such as, for example,drillpipe connectors, OCTG specialty type box and pin connectors, aratchet-latch type connector or a standard box by pin connector. In apreferred embodiment, the drillpipe 1905 is removably coupled to theinnerstring adapter 1910 by a drillpipe connection.

[0433] The drillpipe 1905 preferably includes a fluid passage 1975 thatis adapted to convey fluidic materials from a surface location into thefluid passage 1980. In a preferred embodiment, the fluid passage 1975 isadapted to convey fluidic materials such as, for example, cement,drilling mud, epoxy or lubricants at operating pressures and flow ratesranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute.

[0434] The innerstring adapter 1910 is coupled to the drill string 1905and the sealing sleeve 1915. The innerstring adapter 1910 preferablycomprises a substantially hollow tubular member or members. Theinnerstring adapter 1910 may be fabricated from any number ofconventional commercially available materials such as, for example, oilcountry tubular goods, low alloy steel, carbon steel, stainless steel orother high strength materials. In a preferred embodiment, theinnerstring adapter 1910 is fabricated from oilfield country tubulargoods in order to optimally provide mechanical properties that closelymatch those of the drill string 1905.

[0435] The innerstring adapter 1910 may be coupled to the drill string1905 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connectors, oilfield countrytubular goods specialty type threaded connectors, ratchet-latch typestab in connector, or a standard threaded connection. In a preferredembodiment, the innerstring adapter 1910 is removably coupled to thedrill pipe 1905 by a drillpipe connection. The innerstring adapter 1910may be coupled to the sealing sleeve 1915 using any number ofconventional commercially available mechanical couplings such as, forexample, drillpipe connection, oilfield country tubular goods specialtytype threaded connector, ratchet-latch type stab in connectors, or astandard threaded connection. In a preferred embodiment, the innerstringadapter 1910 is removably coupled to the sealing sleeve 1915 by astandard threaded connection.

[0436] The innerstring adapter 1910 preferably includes a fluid passage1980 that is adapted to convey fluidic materials from the fluid passage1975 into the fluid passage 1985. In a preferred embodiment, the fluidpassage 1980 is adapted to convey fluidic materials such as, forexample, cement, drilling mud, epoxy, or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0437] The sealing sleeve 1915 is coupled to the innerstring adapter1910 and the inner sealing mandrel 1920. The sealing sleeve 1915preferably comprises a substantially hollow tubular member or members.The sealing sleeve 1915 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, carbon steel, low alloy steel, stainlesssteel or other high strength materials. In a preferred embodiment, thesealing sleeve 1915 is fabricated from oilfield country tubular goods inorder to optimally provide mechanical properties that substantiallymatch the remaining components of the apparatus 1900.

[0438] The sealing sleeve 1915 may be coupled to the innerstring adapter1910 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, ratchet-latch typestab in connection, or a standard threaded connection. In a preferredembodiment, the sealing sleeve 1915 is removably coupled to theinnerstring adapter 1910 by a standard threaded connection. The sealingsleeve 1915 may be coupled to the inner sealing mandrel 1920 using anynumber of conventional commercially available mechanical couplings suchas, for example, drillpipe connection, oilfield country tubular goodsspecialty type threaded connection, or a standard threaded connection.In a preferred embodiment, the sealing sleeve 1915 is removably coupledto the inner sealing mandrel 1920 by a standard threaded connection.

[0439] The sealing sleeve 1915 preferably includes a fluid passage 1985that is adapted to convey fluidic materials from the fluid passage 1980into the fluid passage 1990. In a preferred embodiment, the fluidpassage 1985 is adapted to convey fluidic materials such as, forexample, cement, drilling mud, epoxy or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0440] The inner sealing mandrel 1920 is coupled to the sealing sleeve1915 and the lower sealing head 1930. The inner sealing mandrel 1920preferably comprises a substantially hollow tubular member or members.The inner sealing mandrel 1920 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, stainless steel, low alloy steel, carbonsteel or other similar high strength materials. In a preferredembodiment, the inner sealing mandrel 1920 is fabricated from stainlesssteel in order to optimally provide mechanical properties similar to theother components of the apparatus 1900 while also providing a smoothouter surface to support seals and other moving parts that can operatewith minimal wear, corrosion and pitting.

[0441] The inner sealing mandrel 1920 may be coupled to the sealingsleeve 1915 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection, or astandard threaded connection. In a preferred embodiment, the innersealing mandrel 1920 is removably coupled to the sealing sleeve 1915 bya standard threaded connections. The inner sealing mandrel 1920 may becoupled to the lower sealing head 1930 using any number of conventionalcommercially available mechanical couplings such as, for example,drillpipe connection, oilfield country tubular goods specialty typethreaded connection, ratchet-latch type stab in connectors or standardthreaded connections. In a preferred embodiment, the inner sealingmandrel 1920 is removably coupled to the lower sealing head 1930 by astandard threaded connections connection.

[0442] The inner sealing mandrel 1920 preferably includes a fluidpassage 1990 that is adapted to convey fluidic materials from the fluidpassage 1985 into the fluid passage 1995. In a preferred embodiment, thefluid passage 1990 is adapted to convey fluidic materials such as, forexample, cement, drilling mud, epoxy or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0443] The upper sealing head 1925 is coupled to the outer sealingmandrel 1935 and the expansion cone 1945. The upper sealing head 1925 isalso movably coupled to the outer surface of the inner sealing mandrel1920 and the inner surface of the casing 1970. In this manner, the uppersealing head 1925, outer sealing mandrel 1935, and the expansion cone1945 reciprocate in the axial direction. The radial clearance betweenthe inner cylindrical surface of the upper sealing head 1925 and theouter surface of the inner sealing mandrel 1920 may range, for example,from about 0.025 to 0.05 inches. In a preferred embodiment, the radialclearance between the inner cylindrical surface of the upper sealinghead 1925 and the outer surface of the inner sealing mandrel 1920 rangesfrom about 0.005 to 0.01 inches in order to optimally provide clearancefor pressure seal placement. The radial clearance between the outercylindrical surface of the upper sealing head 1925 and the inner surfaceof the casing 1970 may range, for example, from about 0.025 to 0.375inches. In a preferred embodiment, the radial clearance between theouter cylindrical surface of the upper sealing head 1925 and the innersurface of the casing 1970 ranges from about 0.025 to 0.125 inches inorder to optimally provide stabilization for the expansion cone 1945 asthe expansion cone 1945 is upwardly moved inside the casing 1970.

[0444] The upper sealing head 1925 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Theupper sealing head 1925 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, stainless steel, machine tool steel, orsimilar high strength materials. In a preferred embodiment, the uppersealing head 1925 is fabricated from stainless steel in order tooptimally provide high strength and smooth outer surfaces that areresistant to wear, galling, corrosion and pitting.

[0445] The inner surface of the upper sealing head 1925 preferablyincludes one or more annular sealing members 2000 for sealing theinterface between the upper sealing head 1925 and the inner sealingmandrel 1920. The sealing members 2000 may comprise any number ofconventional commercially available annular sealing members such as, forexample, o-rings, polypak seals or metal spring energized seals. In apreferred embodiment, the sealing members 2000 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial motion.

[0446] In a preferred embodiment, the upper sealing head 1925 includes ashoulder 2005 for supporting the upper sealing head 1925 on the lowersealing head 1930.

[0447] The upper sealing head 1925 may be coupled to the outer sealingmandrel 1935 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection, or astandard threaded connections. In a preferred embodiment, the uppersealing head 1925 is removably coupled to the outer sealing mandrel 1935by a standard threaded connections. In a preferred embodiment, themechanical coupling between the upper sealing head 1925 and the outersealing mandrel 1935 includes one or more sealing members 2010 forfluidicly sealing the interface between the upper sealing head 1925 andthe outer sealing mandrel 1935. The sealing members 2010 may compriseany number of conventional commercially available sealing members suchas, for example, o-rings, polypak seals or metal spring energized seals.In a preferred embodiment, the sealing members 2010 comprise polypakseals available from Parker Seals in order to optimally provide sealingfor a long axial stroking motion.

[0448] The lower sealing head 1930 is coupled to the inner sealingmandrel 1920 and the load mandrel 1940. The lower sealing head 1930 isalso movably coupled to the inner surface of the outer sealing mandrel1935. In this manner, the upper sealing head 1925 and outer sealingmandrel 1935 reciprocate in the axial direction. The radial clearancebetween the outer surface of the lower sealing head 1930 and the innersurface of the outer sealing mandrel 1935 may range, for example, fromabout 0.025 to 0.05 inches. In a preferred embodiment, the radialclearance between the outer surface of the lower sealing head 1930 andthe inner surface of the outer sealing mandrel 1935 ranges from about0.005 to 0.010 inches in order to optimally provide a close tolerancehaving room for the installation of pressure seal rings.

[0449] The lower sealing head 1930 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Thelower sealing head 1930 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, stainless steel, machine tool steel orother similar high strength materials. In a preferred embodiment, thelower sealing head 1930 is fabricated from stainless steel in order tooptimally provide high strength and resistance to wear, galling,corrosion, and pitting.

[0450] The outer surface of the lower sealing head 1930 preferablyincludes one or more annular sealing members 2015 for sealing theinterface between the lower sealing head 1930 and the outer sealingmandrel 1935. The sealing members 2015 may comprise any number ofconventional commercially available annular sealing members such as, forexample, o-rings, polypak seals, or metal spring energized seals. In apreferred embodiment, the sealing members 2015 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial stroke.

[0451] The lower sealing head 1930 may be coupled to the inner sealingmandrel 1920 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection,welding, amorphous bonding or a standard threaded connection. In apreferred embodiment, the lower sealing head 1930 is removably coupledto the inner sealing mandrel 1920 by a standard threaded connection.

[0452] In a preferred embodiment, the mechanical coupling between thelower sealing head 1930 and the inner sealing mandrel 1920 includes oneor more sealing members 2020 for fluidicly sealing the interface betweenthe lower sealing head 1930 and the inner sealing mandrel 1920. Thesealing members 2020 may comprise any number of conventionalcommercially available sealing members such as, for example, o-rings,polypak seals, or metal spring energized seals. In a preferredembodiment, the sealing members 2020 comprise polypak seals availablefrom Parker Seals in order to optimally provide sealing for a long axialmotion.

[0453] The lower sealing head 1930 may be coupled to the load mandrel1940 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connections, welding, amorphousbonding or a standard threaded connection. In a preferred embodiment,the lower sealing head 1930 is removably coupled to the load mandrel1940 by a standard threaded connection. In a preferred embodiment, themechanical coupling between the lower sealing head 1930 and the loadmandrel 1940 includes one or more sealing members 2025 for fluidiclysealing the interface between the lower sealing head 1930 and the loadmandrel 1940. The sealing members 2025 may comprise any number ofconventional commercially available sealing members such as, forexample, o-rings, polypak seals, or metal spring energized seals. In apreferred embodiment, the sealing members 2025 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial stroke.

[0454] In a preferred embodiment, the lower sealing head 1930 includes athroat passage 2040 fluidicly coupled between the fluid passages 1990and 1995. The throat passage 2040 is preferably of reduced size and isadapted to receive and engage with a plug 2045, or other similar device.In this manner, the fluid passage 1990 is fluidicly isolated from thefluid passage 1995. In this manner, the pressure chamber 2030 ispressurized.

[0455] The outer sealing mandrel 1935 is coupled to the upper sealinghead 1925 and the expansion cone 1945. The outer sealing mandrel 1935 isalso movably coupled to the inner surface of the casing 1970 and theouter surface of the lower sealing head 1930. In this manner, the uppersealing head 1925, outer sealing mandrel 1935, and the expansion cone1945 reciprocate in the axial direction. The radial clearance betweenthe outer surface of the outer sealing mandrel 1935 and the innersurface of the casing 1970 may range, for example, from about 0.025 to0.375 inches. In a preferred embodiment, the radial clearance betweenthe outer surface of the outer sealing mandrel 1935 and the innersurface of the casing 1970 ranges from about 0.025 to 0.125 inches inorder to optimally provide maximum piston surface area to maximize theradial expansion force. The radial clearance between the inner surfaceof the outer sealing mandrel 1935 and the outer surface of the lowersealing head 1930 may range, for example, from about 0.025 to 0.05inches. In a preferred embodiment, the radial clearance between theinner surface of the outer sealing mandrel 1935 and the outer surface ofthe lower sealing head 1930 ranges from about 0.005 to 0.010 inches inorder to optimally provide a minimum gap for the sealing elements tobridge and seal.

[0456] The outer sealing mandrel 1935 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Theouter sealing mandrel 1935 may be fabricated from any number ofconventional commercially available materials such as, for example, lowalloy steel, carbon steel, 13 chromium steel or stainless steel. In apreferred embodiment, the outer sealing mandrel 1935 is fabricated fromstainless steel in order to optimally provide maximum strength andminimum wall thickness while also providing resistance to corrosion,galling and pitting.

[0457] The outer sealing mandrel 1935 may be coupled to the uppersealing head 1925 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, standard threaded connections, or welding. In a preferredembodiment, the outer sealing mandrel 1935 is removably coupled to theupper sealing head 1925 by a standard threaded connections connection.The outer sealing mandrel 1935 may be coupled to the expansion cone 1945using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, or a standard threadedconnections connection, or welding. In a preferred embodiment, the outersealing mandrel 1935 is removably coupled to the expansion cone 1945 bya standard threaded connections connection.

[0458] The upper sealing head 1925, the lower sealing head 1930, theinner sealing mandrel 1920, and the outer sealing mandrel 1935 togetherdefine a pressure chamber 2030. The pressure chamber 2030 is fluidiclycoupled to the passage 1990 via one or more passages 2035. Duringoperation of the apparatus 1900, the plug 2045 engages with the throatpassage 2040 to fluidicly isolate the fluid passage 1990 from the fluidpassage 1995. The pressure chamber 2030 is then pressurized which inturn causes the upper sealing head 1925, outer sealing mandrel 1935, andexpansion cone 1945 to reciprocate in the axial direction. The axialmotion of the expansion cone 1945 in turn expands the casing 1970 in theradial direction.

[0459] The load mandrel 1940 is coupled to the lower sealing head 1930and the mechanical slip body 1955. The load mandrel 1940 preferablycomprises an annular member having substantially cylindrical inner andouter surfaces. The load mandrel 1940 may be fabricated from any numberof conventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the load mandrel 1940 is fabricated from oilfield countrytubular goods in order to optimally provide high strength.

[0460] The load mandrel 1940 may be coupled to the lower sealing head1930 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, welding, amorphousbonding or a standard threaded connection. In a preferred embodiment,the load mandrel 1940 is removably coupled to the lower sealing head1930 by a standard threaded connection. The load mandrel 1940 may becoupled to the mechanical slip body 1955 using any number ofconventional commercially available mechanical couplings such as, forexample, a drillpipe connection, oilfield country tubular goodsspecialty type threaded connections, welding, amorphous bonding, or astandard threaded connections connection. In a preferred embodiment, theload mandrel 1940 is removably coupled to the mechanical slip body 1955by a standard threaded connections connection.

[0461] The load mandrel 1940 preferably includes a fluid passage 1995that is adapted to convey fluidic materials from the fluid passage 1990to the region outside of the apparatus 1900. In a preferred embodiment,the fluid passage 1995 is adapted to convey fluidic materials such as,for example, cement, epoxy, water, drilling mud, or lubricants atoperating pressures and flow rates ranging from about 0 to 9,000 psi and0 to 3,000 gallons/minute.

[0462] The expansion cone 1945 is coupled to the outer sealing mandrel1935. The expansion cone 1945 is also movably coupled to the innersurface of the casing 1970. In this manner, the upper sealing head 1925,outer sealing mandrel 1935, and the expansion cone 1945 reciprocate inthe axial direction. The reciprocation of the expansion cone 1945 causesthe casing 1970 to expand in the radial direction.

[0463] The expansion cone 1945 preferably comprises an annular memberhaving substantially cylindrical inner and conical outer surfaces. Theoutside radius of the outside conical surface may range, for example,from about 2 to 34 inches. In a preferred embodiment, the outside radiusof the outside conical surface ranges from about 3 to 28 inches in orderto optimally provide cone dimensions for the typical range of tubularmembers.

[0464] The axial length of the expansion cone 1945 may range, forexample, from about 2 to 8 times the largest outer diameter of theexpansion cone 1945. In a preferred embodiment, the axial length of theexpansion cone 1945 ranges from about 3 to 5 times the largest outerdiameter of the expansion cone 1945 in order to optimally providestability and centralization of the expansion cone 1945 during theexpansion process. In a preferred embodiment, the angle of attack of theexpansion cone 1945 ranges from about 5 to 30 degrees in order tooptimally balance friction forces with the desired amount of radialexpansion. The expansion cone 1945 angle of attack will vary as afunction of the operating parameters of the particular expansionoperation.

[0465] The expansion cone 1945 may be fabricated from any number ofconventional commercially available materials such as, for example,machine tool steel, ceramics, tungsten carbide, nitride steel, or othersimilar high strength materials. In a preferred embodiment, theexpansion cone 1945 is fabricated from D2 machine tool steel in order tooptimally provide high strength and resistance to corrosion, wear,galling, and pitting. In a particularly preferred embodiment, theoutside surface of the expansion cone 1945 has a surface hardnessranging from about 58 to 62 Rockwell C in order to optimally providehigh strength and resist wear and galling.

[0466] The expansion cone 1945 may be coupled to the outside sealingmandrel 1935 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield tubular country goods specialty type threaded connection,welding, amorphous bonding, or a standard threaded connectionsconnection. In a preferred embodiment, the expansion cone 1945 iscoupled to the outside sealing mandrel 1935 using a standard threadedconnections connection in order to optimally provide connector strengthfor the typical operating loading conditions while also permitting easyreplacement of the expansion cone 1945.

[0467] The mandrel launcher 1950 is coupled to the casing 1970. Themandrel launcher 1950 comprises a tubular section of casing having areduced wall thickness compared to the casing 1970. In a preferredembodiment, the wall thickness of the mandrel launcher is about 50 to100% of the wall thickness of the casing 1970. In this manner, theinitiation of the radial expansion of the casing 1970 is facilitated,and the insertion of the larger outside diameter mandrel launcher 1950into the wellbore and/or casing is facilitated.

[0468] The mandrel launcher 1950 may be coupled to the casing 1970 usingany number of conventional mechanical couplings. The mandrel launcher1950 may have a wall thickness ranging, for example, from about 0.15 to1.5 inches. In a preferred embodiment, the wall thickness of the mandrellauncher 1950 ranges from about 0.25 to 0.75 inches in order tooptimally provide high strength with a small overall profile. Themandrel launcher 1950 may be fabricated from any number of conventionalcommercially available materials such as, for example, oil field tubulargoods, low alloy steel, carbon steel, stainless steel or other similarhigh strength materials. In a preferred embodiment, the mandrel launcher1950 is fabricated from oil field tubular goods of higher strength butlower wall thickness than the casing 1970 in order to optimally providea thin walled container with approximately the same burst strength asthe casing 1970.

[0469] The mechanical slip body 1955 is coupled to the load mandrel1970, the mechanical slips 1960, and the drag blocks 1965. Themechanical slip body 1955 preferably comprises a tubular member havingan inner passage 2050 fluidicly coupled to the passage 1995. In thismanner, fluidic materials may be conveyed from the passage 2050 to aregion outside of the apparatus 1900.

[0470] The mechanical slip body 1955 may be coupled to the load mandrel1940 using any number of conventional mechanical couplings. In apreferred embodiment, the mechanical slip body 1955 is removably coupledto the load mandrel 1940 using a standard threaded connection in orderto optimally provide high strength and permit the mechanical slip body1955 to be easily replaced. The mechanical slip body 1955 may be coupledto the mechanical slips 1955 using any number of conventional mechanicalcouplings. In a preferred embodiment, the mechanical slip body 1955 isremovably coupled to the mechanical slips 1955 using threads and slidingsteel retainer rings in order to optimally provide high strengthcoupling and also permit easy replacement of the mechanical slips 1955.The mechanical slip body 1955 may be coupled to the drag blocks 1965using any number of conventional mechanical couplings. In a preferredembodiment, the mechanical slip body 1955 is removably coupled to thedrag blocks 1965 using threaded connections and sliding steel retainerrings in order to optimally provide high strength and also permit easyreplacement of the drag blocks 1965.

[0471] The mechanical slips 1960 are coupled to the outside surface ofthe mechanical slip body 1955. During operation of the apparatus 1900,the mechanical slips 1960 prevent upward movement of the casing 1970 andmandrel launcher 1950. In this manner, during the axial reciprocation ofthe expansion cone 1945, the casing 1970 and mandrel launcher 1950 aremaintained in a substantially stationary position. In this manner, themandrel launcher 1950 and casing 1970 are expanded in the radialdirection by the axial movement of the expansion cone 1945.

[0472] The mechanical slips 1960 may comprise any number of conventionalcommercially available mechanical slips such as, for example, RTTSpacker tungsten carbide mechanical slips, RTTS packer wicker typemechanical slips or Model 3L retrievable bridge plug tungsten carbideupper mechanical slips. In a preferred embodiment, the mechanical slips1960 comprise RTTS packer tungsten carbide mechanical slips availablefrom Halliburton Energy Services in order to optimally provideresistance to axial movement of the casing 1970 during the expansionprocess.

[0473] The drag blocks 1965 are coupled to the outside surface of themechanical slip body 1955. During operation of the apparatus 1900, thedrag blocks 1965 prevent upward movement of the casing 1970 and mandrellauncher 1950. In this manner, during the axial reciprocation of theexpansion cone 1945, the casing 1970 and mandrel launcher 1950 aremaintained in a substantially stationary position. In this manner, themandrel launcher 1950 and casing 1970 are expanded in the radialdirection by the axial movement of the expansion cone 1945.

[0474] The drag blocks 1965 may comprise any number of conventionalcommercially available mechanical slips such as, for example, RTTSpacker tungsten carbide mechanical slips, RTTS packer wicker typemechanical slips or Model 3L retrievable bridge plug tungsten carbideupper mechanical slips. In a preferred embodiment, the drag blocks 1965comprise RTTS packer tungsten carbide mechanical slips available fromHalliburton Energy Services in order to optimally provide resistance toaxial movement of the casing 1970 during the expansion process.

[0475] The casing 1970 is coupled to the mandrel launcher 1950. Thecasing 1970 is further removably coupled to the mechanical slips 1960and drag blocks 1965. The casing 1970 preferably comprises a tubularmember. The casing 1970 may be fabricated from any number ofconventional commercially available materials such as, for example,slotted tubulars, oil field country tubular goods, low alloy steel,carbon steel, stainless steel or other similar high strength materials.In a preferred embodiment, the casing 1970 is fabricated from oilfieldcountry tubular goods available from various foreign and domestic steelmills in order to optimally provide high strength. In a preferredembodiment, the upper end of the casing 1970 includes one or moresealing members positioned about the exterior of the casing 1970.

[0476] During operation, the apparatus 1900 is positioned in a wellborewith the upper end of the casing 1970 positioned in an overlappingrelationship within an existing wellbore casing. In order minimize surgepressures within the borehole during placement of the apparatus 1900,the fluid passage 1975 is preferably provided with one or more pressurerelief passages. During the placement of the apparatus 1900 in thewellbore, the casing 1970 is supported by the expansion cone 1945.

[0477] After positioning of the apparatus 1900 within the bore hole inan overlapping relationship with an existing section of wellbore casing,a first fluidic material is pumped into the fluid passage 1975 from asurface location. The first fluidic material is conveyed from the fluidpassage 1975 to the fluid passages 1980, 1985, 1990, 1995, and 2050. Thefirst fluidic material will then exit the apparatus and fill the annularregion between the outside of the apparatus 1900 and the interior wallsof the bore hole.

[0478] The first fluidic material may comprise any number ofconventional commercially available materials such as, for example,drilling mud, water, epoxy or cement. In a preferred embodiment, thefirst fluidic material comprises a hardenable fluidic sealing materialsuch as, for example, cement or epoxy. In this manner, a wellbore casinghaving an outer annular layer of a hardenable material may be formed.

[0479] The first fluidic material may be pumped into the apparatus 1900at operating pressures and flow rates ranging, for example, from about 0to 4,500 psi, and 0 to 3,000 gallons/minute. In a preferred embodiment,the first fluidic material is pumped into the apparatus 1900 atoperating pressures and flow rates ranging from about 0 to 4,500 psi and0 to 3,000 gallons/minute in order to optimally provide operatingpressures and flow rates for typical operating conditions.

[0480] At a predetermined point in the injection of the first fluidicmaterial such as, for example, after the annular region outside of theapparatus 1900 has been filled to a predetermined level, a plug 2045,dart, or other similar device is introduced into the first fluidicmaterial. The plug 2045 lodges in the throat passage 2040 therebyfluidicly isolating the fluid passage 1990 from the fluid passage 1995.

[0481] After placement of the plug 2045 in the throat passage 2040, asecond fluidic material is pumped into the fluid passage 1975 in orderto pressurize the pressure chamber 2030. The second fluidic material maycomprise any number of conventional commercially available materialssuch as, for example, water, drilling gases, drilling mud or lubricant.In a preferred embodiment, the second fluidic material comprises anon-hardenable fluidic material such as, for example, water, drillingmud or lubricant in order minimize frictional forces.

[0482] The second fluidic material may be pumped into the apparatus 1900at operating pressures and flow rates ranging, for example, from about 0to 4,500 psi and 0 to 4,500 gallons/minute. In a preferred embodiment,the second fluidic material is pumped into the apparatus 1900 atoperating pressures and flow rates ranging from about 0 to 3,500 psi,and 0 to 1,200 gallons/minute in order to optimally provide expansion ofthe casing 1970.

[0483] The pressurization of the pressure chamber 2030 causes the uppersealing head 1925, outer sealing mandrel 1935, and expansion cone 1945to move in an axial direction. As the expansion cone 1945 moves in theaxial direction, the expansion cone 1945 pulls the mandrel launcher 1950and drag blocks 1965 along, which sets the mechanical slips 1960 andstops further axial movement of the mandrel launcher 1950 and casing1970. In this manner, the axial movement of the expansion cone 1945radially expands the mandrel launcher 1950 and casing 1970.

[0484] Once the upper sealing head 1925, outer sealing mandrel 1935, andexpansion cone 1945 complete an axial stroke, the operating pressure ofthe second fluidic material is reduced and the drill string 1905 israised. This causes the inner sealing mandrel 1920, lower sealing head1930, load mandrel 1940, and mechanical slip body 1955 to move upward.This unsets the mechanical slips 1960 and permits the mechanical slips1960 and drag blocks 1965 to be moved upward within the mandrel launcherand casing 1970. When the lower sealing head 1930 contacts the uppersealing head 1925, the second fluidic material is again pressurized andthe radial expansion process continues. In this manner, the mandrellauncher 1950 and casing 1970 are radial expanded through repeated axialstrokes of the upper sealing head 1925, outer sealing mandrel 1935 andexpansion cone 1945. Throughput the radial expansion process, the upperend of the casing 1970 is preferably maintained in an overlappingrelation with an existing section of wellbore casing.

[0485] At the end of the radial expansion process, the upper end of thecasing 1970 is expanded into intimate contact with the inside surface ofthe lower end of the existing wellbore casing. In a preferredembodiment, the sealing members provided at the upper end of the casing1970 provide a fluidic seal between the outside surface of the upper endof the casing 1970 and the inside surface of the lower end of theexisting wellbore casing. In a preferred embodiment, the contactpressure between the casing 1970 and the existing section of wellborecasing ranges from about 400 to 10,000 psi in order to optimally providecontact pressure for activating sealing members, provide optimalresistance to axial movement of the expanded casing 1970, and optimallysupport typical tensile and compressive loads.

[0486] In a preferred embodiment, as the expansion cone 1945 nears theend of the casing 1970, the operating flow rate of the second fluidicmaterial is reduced in order to minimize shock to the apparatus 1900. Inan alternative embodiment, the apparatus 1900 includes a shock absorberfor absorbing the shock created by the completion of the radialexpansion of the casing 1970.

[0487] In a preferred embodiment, the reduced operating pressure of thesecond fluidic material ranges from about 100 to 1,000 psi as theexpansion cone 1945 nears the end of the casing 1970 in order tooptimally provide reduced axial movement and velocity of the expansioncone 1945. In a preferred embodiment, the operating pressure of thesecond fluidic material is reduced during the return stroke of theapparatus 1900 to the range of about 0 to 500 psi in order minimize theresistance to the movement of the expansion cone 1945. In a preferredembodiment, the stroke length of the apparatus 1900 ranges from about 10to 45 feet in order to optimally provide equipment lengths that can behandled by typical oil well rigging equipment while also minimizing thefrequency at which the expansion cone 1945 must be stopped so theapparatus 1900 can be re-stroked for further expansion operations.

[0488] In an alternative embodiment, at least a portion of the uppersealing head 1925 includes an expansion cone for radially expanding themandrel launcher 1950 and casing 1970 during operation of the apparatus1900 in order to increase the surface area of the casing 1970 acted uponduring the radial expansion process. In this manner, the operatingpressures can be reduced.

[0489] In an alternative embodiment, mechanical slips are positioned inan axial location between the sealing sleeve 1915 and the inner sealingmandrel 1920 in order to simplify the operation and assembly of theapparatus 1900.

[0490] Upon the complete radial expansion of the casing 1970, ifapplicable, the first fluidic material is permitted to cure within theannular region between the outside of the expanded casing 1970 and theinterior walls of the wellbore. In the case where the expanded casing1970 is slotted, the cured fluidic material will preferably permeate andenvelop the expanded casing. In this manner, a new section of wellborecasing is formed within a wellbore. Alternatively, the apparatus 1900may be used to join a first section of pipeline to an existing sectionof pipeline. Alternatively, the apparatus 1900 may be used to directlyline the interior of a wellbore with a casing, without the use of anouter annular layer of a hardenable material. Alternatively, theapparatus 1900 may be used to expand a tubular support member in a hole.

[0491] During the radial expansion process, the pressurized areas of theapparatus 1900 are limited to the fluid passages 1975, 1980, 1985, and1990, and the pressure chamber 2030. No fluid pressure acts directly onthe mandrel launcher 1950 and casing 1970. This permits the use ofoperating pressures higher than the mandrel launcher 1950 and casing1970 could normally withstand.

[0492] Referring now to FIG. 16, a preferred embodiment of an apparatus2100 for forming a mono-diameter wellbore casing will be described. Theapparatus 2100 preferably includes a drillpipe 2105, an innerstringadapter 2110, a sealing sleeve 2115, an inner sealing mandrel 2120,slips 2125, upper sealing head 2130, lower sealing head 2135, outersealing mandrel 2140, load mandrel 2145, expansion cone 2150, and casing2155.

[0493] The drillpipe 2105 is coupled to the innerstring adapter 2110.During operation of the apparatus 2100, the drillpipe 2105 supports theapparatus 2100. The drillpipe 2105 preferably comprises a substantiallyhollow tubular member or members. The drillpipe 2105 may be fabricatedfrom any number of conventional commercially available materials suchas, for example, oilfield country tubular goods, low alloy steel, carbonsteel, stainless steel or other similar high strength material. In apreferred embodiment, the drillpipe 2105 is fabricated from coiledtubing in order to faciliate the placement of the apparatus 1900 innon-vertical wellbores. The drillpipe 2105 may be coupled to theinnerstring adapter 2110 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type connection, or a standard threadedconnection. In a preferred embodiment, the drillpipe 2105 is removablycoupled to the innerstring adapter 2110 by a drill pipe connection.

[0494] The drillpipe 2105 preferably includes a fluid passage 2160 thatis adapted to convey fluidic materials from a surface location into thefluid passage 2165. In a preferred embodiment, the fluid passage 2160 isadapted to convey fluidic materials such as, for example, cement, epoxy,water, drilling mud or lubricants at operating pressures and flow ratesranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute.

[0495] The innerstring adapter 2110 is coupled to the drill string 2105and the sealing sleeve 2115. The innerstring adapter 2110 preferablycomprises a substantially hollow tubular member or members. Theinnerstring adapter 2110 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the innerstring adapter 2110 is fabricated from stainlesssteel in order to optimally provide high strength, low friction, andresistance to corrosion and wear.

[0496] The innerstring adapter 2110 may be coupled to the drill string2105 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, ratchet-latch typeconnection or a standard threaded connection. In a preferred embodiment,the innerstring adapter 2110 is removably coupled to the drill pipe 2105by a drillpipe connection. The innerstring adapter 2110 may be coupledto the sealing sleeve 2115 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection, or a standardthreaded connection. In a preferred embodiment, the innerstring adapter2110 is removably coupled to the sealing sleeve 2115 by a standardthreaded connection.

[0497] The innerstring adapter 2110 preferably includes a fluid passage2165 that is adapted to convey fluidic materials from the fluid passage2160 into the fluid passage 2170. In a preferred embodiment, the fluidpassage 2165 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water drilling muds, or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0498] The sealing sleeve 2115 is coupled to the innerstring adapter2110 and the inner sealing mandrel 2120. The sealing sleeve 2115preferably comprises a substantially hollow tubular member or members.The sealing sleeve 2115 may be fabricated from any number ofconventional commercially available materials such as, for example, oilfield tubular goods, low alloy steel, carbon steel, stainless steel orother similar high strength materials. In a preferred embodiment, thesealing sleeve 2115 is fabricated from stainless steel in order tooptimally provide high strength, low friction surfaces, and resistanceto corrosion, wear, galling, and pitting.

[0499] The sealing sleeve 2115 may be coupled to the innerstring adapter2110 using any number of conventional commercially available mechanicalcouplings such as, for example, a standard threaded connection, oilfieldcountry tubular goods specialty type threaded connections, welding,amorphous bonding, or a standard threaded connection. In a preferredembodiment, the sealing sleeve 2115 is removably coupled to theinnerstring adapter 2110 by a standard threaded connection. The sealingsleeve 2115 may be coupled to the inner sealing mandrel 2120 using anynumber of conventional commercially available mechanical couplings suchas, for example, a standard threaded connection, oilfield countrytubular goods specialty type threaded connections, welding, amorphousbonding, or a standard threaded connection. In a preferred embodiment,the sealing sleeve 2115 is removably coupled to the inner sealingmandrel 2120 by a standard threaded connection.

[0500] The sealing sleeve 2115 preferably includes a fluid passage 2170that is adapted to convey fluidic materials from the fluid passage 2165into the fluid passage 2175. In a preferred embodiment, the fluidpassage 2170 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud, or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0501] The inner sealing mandrel 2120 is coupled to the sealing sleeve2115, slips 2125, and the lower sealing head 2135. The inner sealingmandrel 2120 preferably comprises a substantially hollow tubular memberor members. The inner sealing mandrel 2120 may be fabricated from anynumber of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel or other similar high strength materials. In a preferredembodiment, the inner sealing mandrel 2120 is fabricated from stainlesssteel in order to optimally provide high strength, low frictionsurfaces, and corrosion and wear resistance.

[0502] The inner sealing mandrel 2120 may be coupled to the sealingsleeve 2115 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection, or astandard threaded connection. In a preferred embodiment, the innersealing mandrel 2120 is removably coupled to the sealing sleeve 2115 bya standard threaded connection. The standard threaded connectionprovides high strength and permits easy replacement of components. Theinner sealing mandrel 2120 may be coupled to the slips 2125 using anynumber of conventional commercially available mechanical couplings suchas, for example, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the inner sealing mandrel 2120 isremovably coupled to the slips 2125 by a standard threaded connection.The inner sealing mandrel 2120 may be coupled to the lower sealing head2135 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, welding, amorphousbonding or a standard threaded connection. In a preferred embodiment,the inner sealing mandrel 2120 is removably coupled to the lower sealinghead 2135 by a standard threaded connection.

[0503] The inner sealing mandrel 2120 preferably includes a fluidpassage 2175 that is adapted to convey fluidic materials from the fluidpassage 2170 into the fluid passage 2180. In a preferred embodiment, thefluid passage 2175 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0504] The slips 2125 are coupled to the outer surface of the innersealing mandrel 2120. During operation of the apparatus 2100, the slips2125 preferably maintain the casing 2155 in a substantially stationaryposition during the radial expansion of the casing 2155. In a preferredembodiment, the slips 2125 are activated using the fluid passages 2185to convey pressurized fluid material into the slips 2125.

[0505] The slips 2125 may comprise any number of commercially availablehydraulic slips such as, for example, RTTS packer tungsten carbidehydraulic slips or Model 3L retrievable bridge plug hydraulic slips. Ina preferred embodiment, the slips 2125 comprise RTTS packer tungstencarbide hydraulic slips available from Halliburton Energy Services inorder to optimally provide resistance to axial movement of the casing2155 during the expansion process. In a particularly preferredembodiment, the slips include a fluid passage 2190, pressure chamber2195, spring return 2200, and slip member 2205.

[0506] The slips 2125 may be coupled to the inner sealing mandrel 2120using any number of conventional mechanical couplings. In a preferredembodiment, the slips 2125 are removably coupled to the outer surface ofthe inner sealing mandrel 2120 by a thread connection in order tooptimally provide interchangeability of parts.

[0507] The upper sealing head 2130 is coupled to the outer sealingmandrel 2140 and expansion cone 2150. The upper sealing head 2130 isalso movably coupled to the outer surface of the inner sealing mandrel2120 and the inner surface of the casing 2155. In this manner, the uppersealing head 2130 reciprocates in the axial direction. The radialclearance between the inner cylindrical surface of the upper sealinghead 2130 and the outer surface of the inner sealing mandrel 2120 mayrange, for example, from about 0.025 to 0.05 inches. In a preferredembodiment, the radial clearance between the inner cylindrical surfaceof the upper sealing head 2130 and the outer surface of the innersealing mandrel 2120 ranges from about 0.005 to 0.010 inches in order tooptimally provide a pressure seal. The radial clearance between theouter cylindrical surface of the upper sealing head 2130 and the innersurface of the casing 2155 may range, for example, from about 0.025 to0.375 inches. In a preferred embodiment, the radial clearance betweenthe outer cylindrical surface of the upper sealing head 2130 and theinner surface of the casing 2155 ranges from about 0.025 to 0.125 inchesin order to optimally provide stabilization for the expansion cone 2130during axial movement of the expansion cone 2130.

[0508] The upper sealing head 2130 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Theupper sealing head 2130 may be fabricated from any number ofconventional commercially available materials such as, for example, lowalloy steel, carbon steel, stainless steel or other similar highstrength materials. In a preferred embodiment, the upper sealing head2130 is fabricated from stainless steel in order to optimally providehigh strength, corrosion resistance, and low friction surfaces. Theinner surface of the upper sealing head 2130 preferably includes one ormore annular sealing members 2210 for sealing the interface between theupper sealing head 2130 and the inner sealing mandrel 2120. The sealingmembers 2210 may comprise any number of conventional commerciallyavailable annular sealing members such as, for example, o-rings, polypakseals, or metal spring energized seals. In a preferred embodiment, thesealing members 2210 comprise polypak seals available from Parker Sealsin order to optimally provide sealing for a long axial stroke.

[0509] In a preferred embodiment, the upper sealing head 2130 includes ashoulder 2215 for supporting the upper sealing head 2130 on the lowersealing head 2135.

[0510] The upper sealing head 2130 may be coupled to the outer sealingmandrel 2140 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty threaded connection, welding,amorphous bonding or a standard threaded connection. In a preferredembodiment, the upper sealing head 2130 is removably coupled to theouter sealing mandrel 2140 by a standard threaded connection. In apreferred embodiment, the mechanical coupling between the upper sealinghead 2130 and the outer sealing mandrel 2140 includes one or moresealing members 2220 for fluidicly sealing the interface between theupper sealing head 2130 and the outer sealing mandrel 2140. The sealingmembers 2220 may comprise any number of conventional commerciallyavailable sealing members such as, for example, o-rings, polypak seals,or metal spring energized seals. In a preferred embodiment, the sealingmembers 2220 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for a long axial stroke.

[0511] The lower sealing head 2135 is coupled to the inner sealingmandrel 2120 and the load mandrel 2145. The lower sealing head 2135 isalso movably coupled to the inner surface of the outer sealing mandrel2140. In this manner, the upper sealing head 2130, outer sealing mandrel2140, and expansion cone 2150 reciprocate in the axial direction. Theradial clearance between the outer surface of the lower sealing head2135 and the inner surface of the outer sealing mandrel 2140 may range,for example, from about 0.0025 to 0.05 inches. In a preferredembodiment, the radial clearance between the outer surface of the lowersealing head 2135 and the inner surface of the outer sealing mandrel2140 ranges from about 0.0025 to 0.05 inches in order to optimallyprovide minimal radial clearance.

[0512] The lower sealing head 2135 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Thelower sealing head 2135 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the lower sealing head 2135 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces. The outer surface of the lower sealing head2135 preferably includes one or more annular sealing members 2225 forsealing the interface between the lower sealing head 2135 and the outersealing mandrel 2140. The sealing members 2225 may comprise any numberof conventional commercially available annular sealing members such as,for example, o-rings, polypak seals or metal spring energized seals. Ina preferred embodiment, the sealing members 2225 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial stroke.

[0513] The lower sealing head 2135 may be coupled to the inner sealingmandrel 2120 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection,welding, amorphous bonding, or a standard threaded connection. In apreferred embodiment, the lower sealing head 2135 is removably coupledto the inner sealing mandrel 2120 by a standard threaded connection. Ina preferred embodiment, the mechanical coupling between the lowersealing head 2135 and the inner sealing mandrel 2120 includes one ormore sealing members 2230 for fluidicly sealing the interface betweenthe lower sealing head 2135 and the inner sealing mandrel 2120. Thesealing members 2230 may comprise any number of conventionalcommercially available sealing members such as, for example, o-rings,polypak seals, or metal spring energized seals. In a preferredembodiment, the sealing members 2230 comprise polypak seals availablefrom Parker Seals in order to optimally provide sealing for a long axialstroke.

[0514] The lower sealing head 2135 may be coupled to the load mandrel2145 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty threaded connection, welding, amorphous bonding,or a standard threaded connection. In a preferred embodiment, the lowersealing head 2135 is removably coupled to the load mandrel 2145 by astandard threaded connection. In a preferred embodiment, the mechanicalcoupling between the lower sealing head 2135 and the load mandrel 2145includes one or more sealing members 2235 for fluidicly sealing theinterface between the lower sealing head 1930 and the load mandrel 2145.The sealing members 2235 may comprise any number of conventionalcommercially available sealing members such as, for example, o-rings,polypak seals, or metal spring energized seals. In a preferredembodiment, the sealing members 2235 comprise polypak seals availablefrom Parker Seals in order to optimally provide sealing for a long axialstroke.

[0515] In a preferred embodiment, the lower sealing head 2135 includes athroat passage 2240 fluidicly coupled between the fluid passages 2175and 2180. The throat passage 2240 is preferably of reduced size and isadapted to receive and engage with a plug 2245, or other similar device.In this manner, the fluid passage 2175 is fluidicly isolated from thefluid passage 2180. In this manner, the pressure chamber 2250 ispressurized.

[0516] The outer sealing mandrel 2140 is coupled to the upper sealinghead 2130 and the expansion cone 2150. The outer sealing mandrel 2140 isalso movably coupled to the inner surface of the casing 2155 and theouter surface of the lower sealing head 2135. In this manner, the uppersealing head 2130, outer sealing mandrel 2140, and the expansion cone2150 reciprocate in the axial direction. The radial clearance betweenthe outer surface of the outer sealing mandrel 2140 and the innersurface of the casing 2155 may range, for example, from about 0.025 to0.375 inches. In a preferred embodiment, the radial clearance betweenthe outer surface of the outer sealing mandrel 2140 and the innersurface of the casing 2155 ranges from about 0.025 to 0.125 inches inorder to optimally provide stabilization for the expansion cone 2130during the expansion process. The radial clearance between the innersurface of the outer sealing mandrel 2140 and the outer surface of thelower sealing head 2135 may range, for example, from about 0.005 to0.125 inches. In a preferred embodiment, the radial clearance betweenthe inner surface of the outer sealing mandrel 2140 and the outersurface of the lower sealing head 2135 ranges from about 0.005 to 0.010inches in order to optimally provide minimal radial clearance.

[0517] The outer sealing mandrel 2140 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Theouter sealing mandrel 2140 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel, or other similar high strength materials. In a preferredembodiment, the outer sealing mandrel 2140 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces.

[0518] The outer sealing mandrel 2140 may be coupled to the uppersealing head 2130 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, welding, amorphous bonding or a standard threadedconnection. In a preferred embodiment, the outer sealing mandrel 2140 isremovably coupled to the upper sealing head 2130 by a standard threadedconnection. The outer sealing mandrel 2140 may be coupled to theexpansion cone 2150 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the outer sealing mandrel 2140 isremovably coupled to the expansion cone 2150 by a standard threadedconnection.

[0519] The upper sealing head 2130, the lower sealing head 2135, innersealing mandrel 2120, and the outer sealing mandrel 2140 together definea pressure chamber 2250. The pressure chamber 2250 is fluidicly coupledto the passage 2175 via one or more passages 2255. During operation ofthe apparatus 2100, the plug 2245 engages with the throat passage 2240to fluidicly isolate the fluid passage 2175 from the fluid passage 2180.The pressure chamber 2250 is then pressurized which in turn causes theupper sealing head 2130, outer sealing mandrel 2140, and expansion cone2150 to reciprocate in the axial direction. The axial motion of theexpansion cone 2150 in turn expands the casing 2155 in the radialdirection.

[0520] The load mandrel 2145 is coupled to the lower sealing head 2135.The load mandrel 2145 preferably comprises an annular member havingsubstantially cylindrical inner and outer surfaces. The load mandrel2145 may be fabricated from any number of conventional commerciallyavailable materials such as, for example, oilfield country tubulargoods, low alloy steel, carbon steel, stainless steel or other similarhigh strength materials. In a preferred embodiment, the load mandrel2145 is fabricated from stainless steel in order to optimally providehigh strength, corrosion resistance, and low friction bearing surfaces.

[0521] The load mandrel 2145 may be coupled to the lower sealing head2135 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty threaded connection, welding, amorphous bondingor a standard threaded connection. In a preferred embodiment, the loadmandrel 2145 is removably coupled to the lower sealing head 2135 by astandard threaded connection in order to optimally provide high strengthand permit easy replacement of the load mandrel 2145.

[0522] The load mandrel 2145 preferably includes a fluid passage 2180that is adapted to convey fluidic materials from the fluid passage 2180to the region outside of the apparatus 2100. In a preferred embodiment,the fluid passage 2180 is adapted to convey fluidic materials such as,for example, cement, epoxy, water, drilling mud, or lubricants atoperating pressures and flow rates ranging from about 0 to 9,000 psi and0 to 3,000 gallons/minute.

[0523] The expansion cone 2150 is coupled to the outer sealing mandrel2140. The expansion cone 2150 is also movably coupled to the innersurface of the casing 2155. In this manner, the upper sealing head 2130,outer sealing mandrel 2140, and the expansion cone 2150 reciprocate inthe axial direction. The reciprocation of the expansion cone 2150 causesthe casing 2155 to expand in the radial direction.

[0524] The expansion cone 2150 preferably comprises an annular memberhaving substantially cylindrical inner and conical outer surfaces. Theoutside radius of the outside conical surface may range, for example,from about 2 to 34 inches. In a preferred embodiment, the outside radiusof the outside conical surface ranges from about 3 to 28 inches in orderto optimally provide cone dimensions that are optimal for typicalcasings. The axial length of the expansion cone 2150 may range, forexample, from about 2 to 6 times the largest outside diameter of theexpansion cone 2150. In a preferred embodiment, the axial length of theexpansion cone 2150 ranges from about 3 to 5 times the largest outsidediameter of the expansion cone 2150 in order to optimally providestability and centralization of the expansion cone 2150 during theexpansion process. In a particularly preferred embodiment, the maximumoutside diameter of the expansion cone 2150 is between about 90 to 100%of the inside diameter of the existing wellbore that the casing 2155will be joined with. In a preferred embodiment, the angle of attack ofthe expansion cone 2150 ranges from about 5 to 30 degrees in order tooptimally balance friction forces and radial expansion forces. Theoptimal expansion cone 2150 angle of attack will vary as a function ofthe particular operating conditions of the expansion operation.

[0525] The expansion cone 2150 may be fabricated from any number ofconventional commercially available materials such as, for example,machine tool steel, nitride steel, titanium, tungsten carbide, ceramics,or other similar high strength materials. In a preferred embodiment, theexpansion cone 2150 is fabricated from D2 machine tool steel in order tooptimally provide high strength and resistance to wear and galling. In aparticularly preferred embodiment, the outside surface of the expansioncone 2150 has a surface hardness ranging from about 58 to 62 Rockwell Cin order to optimally provide resistance to wear.

[0526] The expansion cone 2150 may be coupled to the outside sealingmandrel 2140 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection,welding, amorphous bonding or a standard threaded connection. In apreferred embodiment, the expansion cone 2150 is coupled to the outsidesealing mandrel 2140 using a standard threaded connection in order tooptimally provide high strength and permit the expansion cone 2150 to beeasily replaced.

[0527] The casing 2155 is removably coupled to the slips 2125 andexpansion cone 2150. The casing 2155 preferably comprises a tubularmember. The casing 2155 may be fabricated from any number ofconventional commercially available materials such as, for example,slotted tubulars, oilfield country tubular goods, low alloy steel,carbon steel, stainless steel or other similar high strength material.In a preferred embodiment, the casing 2155 is fabricated from oilfieldcountry tubular goods available from various foreign and domestic steelmills in order to optimally provide high strength.

[0528] In a preferred embodiment, the upper end 2260 of the casing 2155includes a thin wall section 2265 and an outer annular sealing member2270. In a preferred embodiment, the wall thickness of the thin wallsection 2265 is about 50 to 100% of the regular wall thickness of thecasing 2155. In this manner, the upper end 2260 of the casing 2155 maybe easily expanded and deformed into intimate contact with the lower endof an existing section of wellbore casing. In a preferred embodiment,the lower end of the existing section of casing also includes a thinwall section. In this manner, the radial expansion of the thin walledsection 2265 of casing 2155 into the thin walled section of the existingwellbore casing results in a wellbore casing having a substantiallyconstant inside diameter.

[0529] The annular sealing member 2270 may be fabricated from any numberof conventional commercially available sealing materials such as, forexample, epoxy, rubber, metal or plastic. In a preferred embodiment, theannular sealing member 2270 is fabricated from StrataLock epoxy in orderto optimally provide compressibility and resistance to wear. The outsidediameter of the annular sealing member 2270 preferably ranges from about70 to 95% of the inside diameter of the lower section of the wellborecasing that the casing 2155 is joined to. In this manner, afterexpansion, the annular sealing member 2270 preferably provides a fluidicseal and also preferably provides sufficient frictional force with theinside surface of the existing section of wellbore casing during theradial expansion of the casing 2155 to support the casing 2155.

[0530] In a preferred embodiment, the lower end 2275 of the casing 2155includes a thin wall section 2280 and an outer annular sealing member2285. In a preferred embodiment, the wall thickness of the thin wallsection 2280 is about 50 to 100% of the regular wall thickness of thecasing 2155. In this manner, the lower end 2275 of the casing 2155 maybe easily expanded and deformed. Furthermore, in this manner, an othersection of casing may be easily joined with the lower end 2275 of thecasing 2155 using a radial expansion process. In a preferred embodiment,the upper end of the other section of casing also includes a thin wallsection. In this manner, the radial expansion of the thin walled sectionof the upper end of the other casing into the thin walled section 2280of the lower end of the casing 2155 results in a wellbore casing havinga substantially constant inside diameter.

[0531] The annular sealing member 2285 may be fabricated from any numberof conventional commercially available sealing materials such as, forexample, epoxy, rubber, metal or plastic. In a preferred embodiment, theannular sealing member 2285 is fabricated from StrataLock epoxy in orderto optimally provide compressibility and wear resistance. The outsidediameter of the annular sealing member 2285 preferably ranges from about70 to 95% of the inside diameter of the lower section of the existingwellbore casing that the casing 2155 is joined to. In this manner, theannular sealing member 2285 preferably provides a fluidic seal and alsopreferably provides sufficient frictional force with the inside wall ofthe wellbore during the radial expansion of the casing 2155 to supportthe casing 2155.

[0532] During operation, the apparatus 2100 is preferably positioned ina wellbore with the upper end 2260 of the casing 2155 positioned in anoverlapping relationship with the lower end of an existing wellborecasing. In a particularly preferred embodiment, the thin wall section2265 of the casing 2155 is positioned in opposing overlapping relationwith the thin wall section and outer annular sealing member of the lowerend of the existing section of wellbore casing. In this manner, theradial expansion of the casing 2155 will compress the thin wall sectionsand annular compressible members of the upper end 2260 of the casing2155 and the lower end of the existing wellbore casing into intimatecontact. During the positioning of the apparatus 2100 in the wellbore,the casing 2155 is supported by the expansion cone 2150.

[0533] After positioning of the apparatus 2100, a first fluidic materialis then pumped into the fluid passage 2160. The first fluidic materialmay comprise any number of conventional commercially available materialssuch as, for example, drilling mud, water, epoxy, or cement. In apreferred embodiment, the first fluidic material comprises a hardenablefluidic sealing material such as, for example, cement or epoxy in orderto provide a hardenable outer annular body around the expanded casing2155.

[0534] The first fluidic material may be pumped into the fluid passage2160 at operating pressures and flow rates ranging, for example, fromabout 0 to 4,500 psi and 0 to 3,000 gallons/minute. In a preferredembodiment, the first fluidic material is pumped into the fluid passage2160 at operating pressures and flow rates ranging from about 0 to 3,500psi and 0 to 1,200 gallons/minute in order to optimally provideoperational efficiency.

[0535] The first fluidic material pumped into the fluid passage 2160passes through the fluid passages 2165, 2170, 2175, 2180 and thenoutside of the apparatus 2100. The first fluidic material then fills theannular region between the outside of the apparatus 2100 and theinterior walls of the wellbore.

[0536] The plug 2245 is then introduced into the fluid passage 2160. Theplug 2245 lodges in the throat passage 2240 and fluidicly isolates andblocks off the fluid passage 2175. In a preferred embodiment, a coupleof volumes of a non-hardenable fluidic material are then pumped into thefluid passage 2160 in order to remove any hardenable fluidic materialcontained within and to ensure that none of the fluid passages areblocked.

[0537] A second fluidic material is then pumped into the fluid passage2160. The second fluidic material may comprise any number ofconventional commercially available materials such as, for example,drilling mud, water, drilling gases, or lubricants. In a preferredembodiment, the second fluidic material comprises a non-hardenablefluidic material such as, for example, water, drilling mud or lubricantin order to optimally provide pressurization of the pressure chamber2250 and minimize frictional forces.

[0538] The second fluidic material may be pumped into the fluid passage2160 at operating pressures and flow rates ranging, for example, fromabout 0 to 4,500 psi and 0 to 4,500 gallons/minute. In a preferredembodiment, the second fluidic material is pumped into the fluid passage2160 at operating pressures and flow rates ranging from about 0 to 3,500psi and 0 to 1,200 gallons/minute in order to optimally provideoperational efficiency.

[0539] The second fluidic material pumped into the fluid passage 2160passes through the fluid passages 2165, 2170, and 2175 into the pressurechambers 2195 of the slips 2125, and into the pressure chamber 2250.Continued pumping of the second fluidic material pressurizes thepressure chambers 2195 and 2250.

[0540] The pressurization of the pressure chambers 2195 causes the slipmembers 2205 to expand in the radial direction and grip the interiorsurface of the casing 2155. The casing 2155 is then preferablymaintained in a substantially stationary position.

[0541] The pressurization of the pressure chamber 2250 causes the uppersealing head 2130, outer sealing mandrel 2140 and expansion cone 2150 tomove in an axial direction relative to the casing 2155. In this manner,the expansion cone 2150 will cause the casing 2155 to expand in theradial direction.

[0542] During the radial expansion process, the casing 2155 is preventedfrom moving in an upward direction by the slips 2125. A length of thecasing 2155 is then expanded in the radial direction through thepressurization of the pressure chamber 2250. The length of the casing2155 that is expanded during the expansion process will be proportionalto the stroke length of the upper sealing head 2130, outer sealingmandrel 2140, and expansion cone 2150.

[0543] Upon the completion of a stroke, the operating pressure of thesecond fluidic material is reduced and the upper sealing head 2130,outer sealing mandrel 2140, and expansion cone 2150 drop to their restpositions with the casing 2155 supported by the expansion cone 2150. Theposition of the drillpipe 2105 is preferably adjusted throughout theradial expansion process in order to maintain the overlappingrelationship between the thin walled sections of the lower end of theexisting wellbore casing and the upper end of the casing 2155. In apreferred embodiment, the stroking of the expansion cone 2150 is thenrepeated, as necessary, until the thin walled section 2265 of the upperend 2260 of the casing 2155 is expanded into the thin walled section ofthe lower end of the existing wellbore casing. In this manner, awellbore casing is formed including two adjacent sections of casinghaving a substantially constant inside diameter. This process may thenbe repeated for the entirety of the wellbore to provide a wellborecasing thousands of feet in length having a substantially constantinside diameter.

[0544] In a preferred embodiment, during the final stroke of theexpansion cone 2150, the slips 2125 are positioned as close as possibleto the thin walled section 2265 of the upper end of the casing 2155 inorder minimize slippage between the casing 2155 and the existingwellbore casing at the end of the radial expansion process.Alternatively, or in addition, the outside diameter of the annularsealing member 2270 is selected to ensure sufficient interference fitwith the inside diameter of the lower end of the existing casing toprevent axial displacement of the casing 2155 during the final stroke.Alternatively, or in addition, the outside diameter of the annularsealing member 2285 is selected to provide an interference fit with theinside walls of the wellbore at an earlier point in the radial expansionprocess so as to prevent further axial displacement of the casing 2155.In this final alternative, the interference fit is preferably selectedto permit expansion of the casing 2155 by pulling the expansion cone2150 out of the wellbore, without having to pressurize the pressurechamber 2250.

[0545] During the radial expansion process, the pressurized areas of theapparatus 2100 are limited to the fluid passages 2160, 2165, 2170, and2175, the pressure chambers 2195 within the slips 2125, and the pressurechamber 2250. No fluid pressure acts directly on the casing 2155. Thispermits the use of operating pressures higher than the casing 2155 couldnormally withstand.

[0546] Once the casing 2155 has been completely expanded off of theexpansion cone 2150, remaining portions of the apparatus 2100 areremoved from the wellbore. In a preferred embodiment, the contactpressure between the deformed thin wall sections and compressibleannular members of the lower end of the existing casing and the upperend 2260 of the casing 2155 ranges from about 500 to 40,000 psi in orderto optimally support the casing 2155 using the existing wellbore casing.

[0547] In this manner, the casing 2155 is radially expanded into contactwith an existing section of casing by pressurizing the interior fluidpassages 2160, 2165, 2170, and 2175 and the pressure chamber 2250 of theapparatus 2100.

[0548] In a preferred embodiment, as required, the annular body ofhardenable fluidic material is then allowed to cure to form a rigidouter annular body about the expanded casing 2155. In the case where thecasing 2155 is slotted, the cured fluidic material preferably permeatesand envelops the expanded casing 2155. The resulting new section ofwellbore casing includes the expanded casing 2155 and the rigid outerannular body. The overlapping joint between the pre-existing wellborecasing and the expanded casing 2155 includes the deformed thin wallsections and the compressible outer annular bodies. The inner diameterof the resulting combined wellbore casings is substantially constant. Inthis manner, a mono-diameter wellbore casing is formed. This process ofexpanding overlapping tubular members having thin wall end portions withcompressible annular bodies into contact can be repeated for the entirelength of a wellbore. In this manner, a mono-diameter wellbore casingcan be provided for thousands of feet in a subterranean formation.

[0549] In a preferred embodiment, as the expansion cone 2150 nears theupper end of the casing 2155, the operating flow rate of the secondfluidic material is reduced in order to minimize shock to the apparatus2100. In an alternative embodiment, the apparatus 2100 includes a shockabsorber for absorbing the shock created by the completion of the radialexpansion of the casing 2155.

[0550] In a preferred embodiment, the reduced operating pressure of thesecond fluidic material ranges from about 100 to 1,000 psi as theexpansion cone 2130 nears the end of the casing 2155 in order tooptimally provide reduced axial movement and velocity of the expansioncone 2130. In a preferred embodiment, the operating pressure of thesecond fluidic material is reduced during the return stroke of theapparatus 2100 to the range of about 0 to 500 psi in order minimize theresistance to the movement of the expansion cone 2130 during the returnstroke. In a preferred embodiment, the stroke length of the apparatus2100 ranges from about 10 to 45 feet in order to optimally provideequipment lengths that can be handled by conventional oil well riggingequipment while also minimizing the frequency at which the expansioncone 2130 must be stopped so that the apparatus 2100 can be re-stroked.

[0551] In an alternative embodiment, at least a portion of the uppersealing head 2130 includes an expansion cone for radially expanding thecasing 2155 during operation of the apparatus 2100 in order to increasethe surface area of the casing 2155 acted upon during the radialexpansion process. In this manner, the operating pressures can bereduced.

[0552] Alternatively, the apparatus 2100 may be used to join a firstsection of pipeline to an existing section of pipeline. Alternatively,the apparatus 2100 may be used to directly line the interior of awellbore with a casing, without the use of an outer annular layer of ahardenable material. Alternatively, the apparatus 2100 may be used toexpand a tubular support member in a hole.

[0553] Referring now to FIGS. 17, 17a and 17 b, another embodiment of anapparatus 2300 for expanding a tubular member will be described. Theapparatus 2300 preferably includes a drillpipe 2305, an innerstringadapter 2310, a sealing sleeve 2315, a hydraulic slip body 2320,hydraulic slips 2325, an inner sealing mandrel 2330, an upper sealinghead 2335, a lower sealing head 2340, a load mandrel 2345, an outersealing mandrel 2350, an expansion cone 2355, a mechanical slip body2360, mechanical slips 2365, drag blocks 2370, casing 2375, fluidpassages 2380, 2385, 2390, 2395, 2400, 2405, 2410, 2415, and 2485, andmandrel launcher 2480.

[0554] The drillpipe 2305 is coupled to the innerstring adapter 2310.During operation of the apparatus 2300, the drillpipe 2305 supports theapparatus 2300. The drillpipe 2305 preferably comprises a substantiallyhollow tubular member or members. The drillpipe 2305 may be fabricatedfrom any number of conventional commercially available materials suchas, for example, oilfield country tubular goods, low alloy steel, carbonsteel, stainless steel or other similar high strength materials. In apreferred embodiment, the drillpipe 2305 is fabricated from coiledtubing in order to faciliate the placement of the apparatus 2300 innon-vertical wellbores. The drillpipe 2305 may be coupled to theinnerstring adapter 2310 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, or a standard threaded connection. In a preferredembodiment, the drillpipe 2305 is removably coupled to the innerstringadapter 2310 by a drillpipe connection.

[0555] The drillpipe 2305 preferably includes a fluid passage 2380 thatis adapted to convey fluidic materials from a surface location into thefluid passage 2385. In a preferred embodiment, the fluid passage 2380 isadapted to convey fluidic materials such as, for example, cement, water,epoxy, drilling muds, or lubricants at operating pressures and flowrates ranging from about 0 to 9,000 psi and 0 to 5,000 gallons/minute inorder to optimally provide operational efficiency.

[0556] The innerstring adapter 2310 is coupled to the drill string 2305and the sealing sleeve 2315. The innerstring adapter 2310 preferablycomprises a substantially hollow tubular member or members. Theinnerstring adapter 2310 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the innerstring adapter 2310 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces.

[0557] The innerstring adapter 2310 may be coupled to the drill string2305 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty threaded connection, or a standard threadedconnection. In a preferred embodiment, the innerstring adapter 2310 isremovably coupled to the drill pipe 2305 by a drillpipe connection. Theinnerstring adapter 2310 may be coupled to the sealing sleeve 2315 usingany number of conventional commercially available mechanical couplingssuch as, for example, a drillpipe connection, oilfield country tubulargoods specialty threaded connection, or a standard threaded connection.In a preferred embodiment, the innerstring adapter 2310 is removablycoupled to the sealing sleeve 2315 by a standard threaded connection.

[0558] The innerstring adapter 2310 preferably includes a fluid passage2385 that is adapted to convey fluidic materials from the fluid passage2380 into the fluid passage 2390. In a preferred embodiment, the fluidpassage 2385 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud, drilling gases orlubricants at operating pressures and flow rates ranging from about 0 to9,000 psi and 0 to 3,000 gallons/minute.

[0559] The sealing sleeve 2315 is coupled to the innerstring adapter2310 and the hydraulic slip body 2320. The sealing sleeve 2315preferably comprises a substantially hollow tubular member or members.The sealing sleeve 2315 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the sealing sleeve 2315 is fabricated from stainless steelin order to optimally provide high strength, corrosion resistance, andlow-friction surfaces.

[0560] The sealing sleeve 2315 may be coupled to the innerstring adapter2310 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connections, oilfield countrytubular goods specialty threaded connections, or a standard threadedconnection. In a preferred embodiment, the sealing sleeve 2315 isremovably coupled to the innerstring adapter 2310 by a standard threadedconnection. The sealing sleeve 2315 may be coupled to the hydraulic slipbody 2320 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty threaded connection, or astandard threaded connection. In a preferred embodiment, the sealingsleeve 2315 is removably coupled to the hydraulic slip body 2320 by astandard threaded connection.

[0561] The sealing sleeve 2315 preferably includes a fluid passage 2390that is adapted to convey fluidic materials from the fluid passage 2385into the fluid passage 2395. In a preferred embodiment, the fluidpassage 2315 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0562] The hydraulic slip body 2320 is coupled to the sealing sleeve2315, the hydraulic slips 2325, and the inner sealing mandrel 2330. Thehydraulic slip body 2320 preferably comprises a substantially hollowtubular member or members. The hydraulic slip body 2320 may befabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, stainless steel or other high strengthmaterial. In a preferred embodiment, the hydraulic slip body 2320 isfabricated from carbon steel in order to optimally provide high strengthat low cost.

[0563] The hydraulic slip body 2320 may be coupled to the sealing sleeve2315 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty threaded connection, or a standard threadedconnection. In a preferred embodiment, the hydraulic slip body 2320 isremovably coupled to the sealing sleeve 2315 by a standard threadedconnection. The hydraulic slip body 2320 may be coupled to the slips2325 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty threaded connection, welding, amorphous bondingor a standard threaded connection. In a preferred embodiment, thehydraulic slip body 2320 is removably coupled to the slips 2325 by astandard threaded connection. The hydraulic slip body 2320 may becoupled to the inner sealing mandrel 2330 using any number ofconventional commercially available mechanical couplings such as, forexample, drillpipe connection, oilfield country tubular goods specialtythreaded connection, welding, amorphous bonding or a standard threadedconnection. In a preferred embodiment, the hydraulic slip body 2320 isremovably coupled to the inner sealing mandrel 2330 by a standardthreaded connection.

[0564] The hydraulic slips body 2320 preferably includes a fluid passage2395 that is adapted to convey fluidic materials from the fluid passage2390 into the fluid passage 2405. In a preferred embodiment, the fluidpassage 2395 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0565] The hydraulic slips body 2320 preferably includes fluid passage2400 that are adapted to convey fluidic materials from the fluid passage2395 into the pressure chambers 2420 of the hydraulic slips 2325. Inthis manner, the slips 2325 are activated upon the pressurization of thefluid passage 2395 into contact with the inside surface of the casing2375. In a preferred embodiment, the fluid passages 2400 are adapted toconvey fluidic materials such as, for example, water, drilling mud orlubricants at operating pressures and flow rates ranging from about 0 to9,000 psi and 0 to 3,000 gallons/minute.

[0566] The slips 2325 are coupled to the outside surface of thehydraulic slip body 2320. During operation of the apparatus 2300, theslips 2325 are activated upon the pressurization of the fluid passage2395 into contact with the inside surface of the casing 2375. In thismanner, the slips 2325 maintain the casing 2375 in a substantiallystationary position.

[0567] The slips 2325 preferably include the fluid passages 2400, thepressure chambers 2420, spring bias 2425, and slip members 2430. Theslips 2325 may comprise any number of conventional commerciallyavailable hydraulic slips such as, for example, RTTS packer tungstencarbide hydraulic slips or Model 3L retrievable bridge plug withhydraulic slips. In a preferred embodiment, the slips 2325 comprise RTTSpacker tungsten carbide hydraulic slips available from HalliburtonEnergy Services in order to optimally provide resistance to axialmovement of the casing 2375 during the radial expansion process.

[0568] The inner sealing mandrel 2330 is coupled to the hydraulic slipbody 2320 and the lower sealing head 2340. The inner sealing mandrel2330 preferably comprises a substantially hollow tubular member ormembers. The inner sealing mandrel 2330 may be fabricated from anynumber of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel or other similar high strength materials. In a preferredembodiment, the inner sealing mandrel 2330 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces.

[0569] The inner sealing mandrel 2330 may be coupled to the hydraulicslip body 2320 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty threaded connection, welding,amorphous bonding, or a standard threaded connection. In a preferredembodiment, the inner sealing mandrel 2330 is removably coupled to thehydraulic slip body 2320 by a standard threaded connection. The innersealing mandrel 2330 may be coupled to the lower sealing head 2340 usingany number of conventional commercially available mechanical couplingssuch as, for example, drillpipe connection, oilfield country tubulargoods specialty threaded connection, welding, amorphous bonding, or astandard threaded connection. In a preferred embodiment, the innersealing mandrel 2330 is removably coupled to the lower sealing head 2340by a standard threaded connection.

[0570] The inner sealing mandrel 2330 preferably includes a fluidpassage 2405 that is adapted to convey fluidic materials from the fluidpassage 2395 into the fluid passage 2415. In a preferred embodiment, thefluid passage 2405 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud, or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0571] The upper sealing head 2335 is coupled to the outer sealingmandrel 2345 and expansion cone 2355. The upper sealing head 2335 isalso movably coupled to the outer surface of the inner sealing mandrel2330 and the inner surface of the casing 2375. In this manner, the uppersealing head 2335 reciprocates in the axial direction. The radialclearance between the inner cylindrical surface of the upper sealinghead 2335 and the outer surface of the inner sealing mandrel 2330 mayrange, for example, from about 0.0025 to 0.05 inches. In a preferredembodiment, the radial clearance between the inner cylindrical surfaceof the upper sealing head 2335 and the outer surface of the innersealing mandrel 2330 ranges from about 0.005 to 0.01 inches in order tooptimally provide minimal clearance. The radial clearance between theouter cylindrical surface of the upper sealing head 2335 and the innersurface of the casing 2375 may range, for example, from about 0.025 to0.375 inches. In a preferred embodiment, the radial clearance betweenthe outer cylindrical surface of the upper sealing head 2335 and theinner surface of the casing 2375 ranges from about 0.025 to 0.125 inchesin order to optimally provide stabilization for the expansion cone 2355during the expansion process.

[0572] The upper sealing head 2335 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Theupper sealing head 2335 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the upper sealing head 2335 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces. The inner surface of the upper sealing head2335 preferably includes one or more annular sealing members 2435 forsealing the interface between the upper sealing head 2335 and the innersealing mandrel 2330. The sealing members 2435 may comprise any numberof conventional commercially available annular sealing members such as,for example, o-rings, polypak seals or metal spring energized seals. Ina preferred embodiment, the sealing members 2435 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial stroke.

[0573] In a preferred embodiment, the upper sealing head 2335 includes ashoulder 2440 for supporting the upper sealing head on the lower sealinghead 1930.

[0574] The upper sealing head 2335 may be coupled to the outer sealingmandrel 2350 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty threaded connection, welding,amorphous bonding, or a standard threaded connection. In a preferredembodiment, the upper sealing head 2335 is removably coupled to theouter sealing mandrel 2350 by a standard threaded connection. In apreferred embodiment, the mechanical coupling between the upper sealinghead 2335 and the outer sealing mandrel 2350 includes one or moresealing members 2445 for fluidicly sealing the interface between theupper sealing head 2335 and the outer sealing mandrel 2350. The sealingmembers 2445 may comprise any number of conventional commerciallyavailable sealing members such as, for example, o-rings, polypak sealsor metal spring energized seals. In a preferred embodiment, the sealingmembers 2445 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for long axial strokes.

[0575] The lower sealing head 2340 is coupled to the inner sealingmandrel 2330 and the load mandrel 2345. The lower sealing head 2340 isalso movably coupled to the inner surface of the outer sealing mandrel2350. In this manner, the upper sealing head 2335 and outer sealingmandrel 2350 reciprocate in the axial direction. The radial clearancebetween the outer surface of the lower sealing head 2340 and the innersurface of the outer sealing mandrel 2350 may range, for example, fromabout 0.0025 to 0.05 inches. In a preferred embodiment, the radialclearance between the outer surface of the lower sealing head 2340 andthe inner surface of the outer sealing mandrel 2350 ranges from about0.005 to 0.010 inches in order to optimally provide minimal radialclearance.

[0576] The lower sealing head 2340 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Thelower sealing head 2340 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield tubular members, low alloy steel, carbon steel, stainless steelor other similar high strength materials. In a preferred embodiment, thelower sealing head 2340 is fabricated from stainless steel in order tooptimally provide high strength, corrosion resistance, and low frictionsurfaces. The outer surface of the lower sealing head 2340 preferablyincludes one or more annular sealing members 2450 for sealing theinterface between the lower sealing head 2340 and the outer sealingmandrel 2350. The sealing members 2450 may comprise any number ofconventional commercially available annular sealing members such as, forexample, o-rings, polypak seals or metal spring energized seals. In apreferred embodiment, the sealing members 2450 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial stroke.

[0577] The lower sealing head 2340 may be coupled to the inner sealingmandrel 2330 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular specialty threaded connection, welding,amorphous bonding, or standard threaded connection. In a preferredembodiment, the lower sealing head 2340 is removably coupled to theinner sealing mandrel 2330 by a standard threaded connection. In apreferred embodiment, the mechanical coupling between the lower sealinghead 2340 and the inner sealing mandrel 2330 includes one or moresealing members 2455 for fluidicly sealing the interface between thelower sealing head 2340 and the inner sealing mandrel 2330. The sealingmembers 2455 may comprise any number of conventional commerciallyavailable sealing members such as, for example, o-rings, polypak ormetal spring energized seals. In a preferred embodiment, the sealingmembers 2455 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for a long axial stroke length.

[0578] The lower sealing head 2340 may be coupled to the load mandrel2345 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty threaded connection, welding, amorphous bondingor a standard threaded connection. In a preferred embodiment, the lowersealing head 2340 is removably coupled to the load mandrel 2345 by astandard threaded connection. In a preferred embodiment, the mechanicalcoupling between the lower sealing head 2340 and the load mandrel 2345includes one or more sealing members 2460 for fluidicly sealing theinterface between the lower sealing head 2340 and the load mandrel 2345.The sealing members 2460 may comprise any number of conventionalcommercially available sealing members such as, for example, o-rings,polypak seals or metal spring energized seals. In a preferredembodiment, the sealing members 2460 comprise polypak seals availablefrom Parker Seals in order to optimally provide sealing for a long axialstroke length.

[0579] In a preferred embodiment, the lower sealing head 2340 includes athroat passage 2465 fluidicly coupled between the fluid passages 2405and 2415. The throat passage 2465 is preferably of reduced size and isadapted to receive and engage with a plug 2470, or other similar device.In this manner, the fluid passage 2405 is fluidicly isolated from thefluid passage 2415. In this manner, the pressure chamber 2475 ispressurized.

[0580] The outer sealing mandrel 2350 is coupled to the upper sealinghead 2335 and the expansion cone 2355. The outer sealing mandrel 2350 isalso movably coupled to the inner surface of the casing 2375 and theouter surface of the lower sealing head 2340. In this manner, the uppersealing head 2335, outer sealing mandrel 2350, and the expansion cone2355 reciprocate in the axial direction. The radial clearance betweenthe outer surface of the outer sealing mandrel 2350 and the innersurface of the casing 2375 may range, for example, from about 0.025 to0.375 inches. In a preferred embodiment, the radial clearance betweenthe outer surface of the outer sealing mandrel 2350 and the innersurface of the casing 2375 ranges from about 0.025 to 0.125 inches inorder to optimally provide stabilization for the expansion cone 2355during the expansion process. The radial clearance between the innersurface of the outer sealing mandrel 2350 and the outer surface of thelower sealing head 2340 may range, for example, from about 0.0025 to0.375 inches. In a preferred embodiment, the radial clearance betweenthe inner surface of the outer sealing mandrel 2350 and the outersurface of the lower sealing head 2340 ranges from about 0.005 to 0.010inches in order to optimally provide minimal clearance.

[0581] The outer sealing mandrel 2350 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Theouter sealing mandrel 2350 may be fabricated from any number ofconventional commercially available materials such as, for example, lowalloy steel, carbon steel, stainless steel or other similar highstrength materials. In a preferred embodiment, the outer sealing mandrel2350 is fabricated from stainless steel in order to optimally providehigh strength, corrosion resistance, and low friction surfaces.

[0582] The outer sealing mandrel 2350 may be coupled to the uppersealing head 2335 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnections, oilfield country tubular goods specialty threadedconnections, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the outer sealing mandrel 2350 isremovably coupled to the upper sealing head 2335 by a standard threadedconnection. The outer sealing mandrel 2350 may be coupled to theexpansion cone 2355 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the outer sealing mandrel 2350 isremovably coupled to the expansion cone 2355 by a standard threadedconnection.

[0583] The upper sealing head 2335, the lower sealing head 2340, theinner sealing mandrel 2330, and the outer sealing mandrel 2350 togetherdefine a pressure chamber 2475. The pressure chamber 2475 is fluidiclycoupled to the passage 2405 via one or more passages 2410. Duringoperation of the apparatus 2300, the plug 2470 engages with the throatpassage 2465 to fluidicly isolate the fluid passage 2415 from the fluidpassage 2405. The pressure chamber 2475 is then pressurized which inturn causes the upper sealing head 2335, outer sealing mandrel 2350, andexpansion cone 2355 to reciprocate in the axial direction. The axialmotion of the expansion cone 2355 in turn expands the casing 2375 in theradial direction.

[0584] The load mandrel 2345 is coupled to the lower sealing head 2340and the mechanical slip body 2360. The load mandrel 2345 preferablycomprises an annular member having substantially cylindrical inner andouter surfaces. The load mandrel 2345 may be fabricated from any numberof conventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the load mandrel 2345 is fabricated from stainless steel inorder to optimally provide high strength, corrosion resistance, and lowfriction surfaces.

[0585] The load mandrel 2345 may be coupled to the lower sealing head2340 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty threaded connection, welding, amorphous bondingor a standard threaded connection. In a preferred embodiment, the loadmandrel 2345 is removably coupled to the lower sealing head 2340 by astandard threaded connection. The load mandrel 2345 may be coupled tothe mechanical slip body 2360 using any number of conventionalcommercially available mechanical couplings such as, for example,drillpipe connection, oilfield country tubular goods specialty threadedconnection, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the load mandrel 2345 isremovably coupled to the mechanical slip body 2360 by a standardthreaded connection.

[0586] The load mandrel 2345 preferably includes a fluid passage 2415that is adapted to convey fluidic materials from the fluid passage 2405to the region outside of the apparatus 2300. In a preferred embodiment,the fluid passage 2415 is adapted to convey fluidic materials such as,for example, cement, epoxy, water, drilling mud or lubricants atoperating pressures and flow rates ranging from about 0 to 9,000 psi and0 to 3,000 gallons/minute.

[0587] The expansion cone 2355 is coupled to the outer sealing mandrel2350. The expansion cone 2355 is also movably coupled to the innersurface of the casing 2375. In this manner, the upper sealing head 2335,outer sealing mandrel 2350, and the expansion cone 2355 reciprocate inthe axial direction. The reciprocation of the expansion cone 2355 causesthe casing 2375 to expand in the radial direction.

[0588] The expansion cone 2355 preferably comprises an annular memberhaving substantially cylindrical inner and conical outer surfaces. Theoutside radius of the outside conical surface may range, for example,from about 2 to 34 inches. In a preferred embodiment, the outside radiusof the outside conical surface ranges from about 3 to 28 inches in orderto optimally provide radial expansion of the typical casings. The axiallength of the expansion cone 2355 may range, for example, from about 2to 8 times the largest outside diameter of the expansion cone 2355. In apreferred embodiment, the axial length of the expansion cone 2355 rangesfrom about 3 to 5 times the largest outside diameter of the expansioncone 2355 in order to optimally provide stability and centralization ofthe expansion cone 2355 during the expansion process. In a preferredembodiment, the angle of attack of the expansion cone 2355 ranges fromabout 5 to 30 degrees in order to optimally frictional forces withradial expansion forces. The optimum angle of attack of the expansioncone 2355 will vary as a function of the operating parameters of theparticular expansion operation.

[0589] The expansion cone 2355 may be fabricated from any number ofconventional commercially available materials such as, for example,machine tool steel, nitride steel, titanium, tungsten carbide, ceramicsor other similar high strength materials. In a preferred embodiment, theexpansion cone 2355 is fabricated from D2 machine tool steel in order tooptimally provide high strength, abrasion resistance, and gallingresistance. In a particularly preferred embodiment, the outside surfaceof the expansion cone 2355 has a surface hardness ranging from about 58to 62 Rockwell C in order to optimally provide high strength, abrasionresistance, resistance to galling.

[0590] The expansion cone 2355 may be coupled to the outside sealingmandrel 2350 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty threaded connection, welding,amorphous bonding, or a standard threaded connection. In a preferredembodiment, the expansion cone 2355 is coupled to the outside sealingmandrel 2350 using a standard threaded connection in order to optimallyprovide high strength and permit the expansion cone 2355 to be easilyreplaced.

[0591] The mandrel launcher 2480 is coupled to the casing 2375. Themandrel launcher 2480 comprises a tubular section of casing having areduced wall thickness compared to the casing 2375. In a preferredembodiment, the wall thickness of the mandrel launcher 2480 is about 50to 100% of the wall thickness of the casing 2375. In this manner, theinitiation of the radial expansion of the casing 2375 is facilitated,and the placement of the apparatus 2300 into a wellbore casing andwellbore is facilitated.

[0592] The mandrel launcher 2480 may be coupled to the casing 2375 usingany number of conventional mechanical couplings. The mandrel launcher2480 may have a wall thickness ranging, for example, from about 0.15 to1.5 inches. In a preferred embodiment, the wall thickness of the mandrellauncher 2480 ranges from about 0.25 to 0.75 inches in order tooptimally provide high strength in a minimal profile. The mandrellauncher 2480 may be fabricated from any number of conventionalcommercially available materials such as, for example, oilfield tubulargoods, low alloy steel, carbon steel, stainless steel or other similarhigh strength materials. In a preferred embodiment, the mandrel launcher2480 is fabricated from oilfield tubular goods having a higher strengththan that of the casing 2375 but with a smaller wall thickness than thecasing 2375 in order to optimally provide a thin walled container havingapproximately the same burst strength as that of the casing 2375.

[0593] The mechanical slip body 2460 is coupled to the load mandrel2345, the mechanical slips 2365, and the drag blocks 2370. Themechanical slip body 2460 preferably comprises a tubular member havingan inner passage 2485 fluidicly coupled to the passage 2415. In thismanner, fluidic materials may be conveyed from the passage 2484 to aregion outside of the apparatus 2300.

[0594] The mechanical slip body 2360 may be coupled to the load mandrel2345 using any number of conventional mechanical couplings. In apreferred embodiment, the mechanical slip body 2360 is removably coupledto the load mandrel 2345 using threads and sliding steel retaining ringsin order to optimally provide a high strength attachment. The mechanicalslip body 2360 may be coupled to the mechanical slips 2365 using anynumber of conventional mechanical couplings. In a preferred embodiment,the mechanical slip body 2360 is removably coupled to the mechanicalslips 2365 using threads and sliding steel retaining rings in order tooptimally provide a high strength attachment. The mechanical slip body2360 may be coupled to the drag blocks 2370 using any number ofconventional mechanical couplings. In a preferred embodiment, themechanical slip body 2360 is removably coupled to the drag blocks 2365using threads and sliding steel retaining rings in order to optimallyprovide a high strength attachment.

[0595] The mechanical slips 2365 are coupled to the outside surface ofthe mechanical slip body 2360. During operation of the apparatus 2300,the mechanical slips 2365 prevent upward movement of the casing 2375 andmandrel launcher 2480. In this manner, during the axial reciprocation ofthe expansion cone 2355, the casing 2375 and mandrel launcher 2480 aremaintained in a substantially stationary position. In this manner, themandrel launcher 2480 and casing 2375 are expanded in the radialdirection by the axial movement of the expansion cone 2355.

[0596] The mechanical slips 2365 may comprise any number of conventionalcommercially available mechanical slips such as, for example, RTTSpacker tungsten carbide mechanical slips, RTTS packer wicker typemechanical slips or Model 3L retrievable bridge plug tungsten carbideupper mechanical slips. In a preferred embodiment, the mechanical slips2365 comprise RTTS packer tungsten carbide mechanical slips availablefrom Halliburton Energy Services in order to optimally provideresistance to axial movement of the casing 2375 during the expansionprocess.

[0597] The drag blocks 2370 are coupled to the outside surface of themechanical slip body 2360. During operation of the apparatus 2300, thedrag blocks 2370 prevent upward movement of the casing 2375 and mandrellauncher 2480. In this manner, during the axial reciprocation of theexpansion cone 2355, the casing 2375 and mandrel launcher 2480 aremaintained in a substantially stationary position. In this manner, themandrel launcher 2480 and casing 2375 are expanded in the radialdirection by the axial movement of the expansion cone 2355.

[0598] The drag blocks 2370 may comprise any number of conventionalcommercially available mechanical slips such as, for example, RTTSpacker mechanical drag blocks or Model 3L retrievable bridge plug dragblocks. In a preferred embodiment, the drag blocks 2370 comprise RTTSpacker mechanical drag blocks available from Halliburton Energy Servicesin order to optimally provide resistance to axial movement of the casing2375 during the expansion process.

[0599] The casing 2375 is coupled to the mandrel launcher 2480. Thecasing 2375 is further removably coupled to the mechanical slips 2365and drag blocks 2370. The casing 2375 preferably comprises a tubularmember. The casing 2375 may be fabricated from any number ofconventional commercially available materials such as, for example,slotted tubulars, oil country tubular goods, carbon steel, low alloysteel, stainless steel or other similar high strength materials. In apreferred embodiment, the casing 2375 is fabricated from oilfieldcountry tubular goods available from various foreign and domestic steelmills in order to optimally provide high strength. In a preferredembodiment, the upper end of the casing 2375 includes one or moresealing members positioned about the exterior of the casing 2375.

[0600] During operation, the apparatus 2300 is positioned in a wellborewith the upper end of the casing 2375 positioned in an overlappingrelationship within an existing wellbore casing. In order minimize surgepressures within the borehole during placement of the apparatus 2300,the fluid passage 2380 is preferably provided with one or more pressurerelief passages. During the placement of the apparatus 2300 in thewellbore, the casing 2375 is supported by the expansion cone 2355.

[0601] After positioning of the apparatus 2300 within the bore hole inan overlapping relationship with an existing section of wellbore casing,a first fluidic material is pumped into the fluid passage 2380 from asurface location. The first fluidic material is conveyed from the fluidpassage 2380 to the fluid passages 2385, 2390, 2395, 2405, 2415, and2485. The first fluidic material will then exit the apparatus 2300 andfill the annular region between the outside of the apparatus 2300 andthe interior walls of the bore hole.

[0602] The first fluidic material may comprise any number ofconventional commercially available materials such as, for example,epoxy, drilling mud, slag mix, cement, or water. In a preferredembodiment, the first fluidic material comprises a hardenable fluidicsealing material such as, for example, slag mix, epoxy, or cement. Inthis manner, a wellbore casing having an outer annular layer of ahardenable material may be formed.

[0603] The first fluidic material may be pumped into the apparatus 2300at operating pressures and flow rates ranging, for example, from about 0to 4,500 psi, and 0 to 3,000 gallons/minute. In a preferred embodiment,the first fluidic material is pumped into the apparatus 2300 atoperating pressures and flow rates ranging from about 0 to 3,500 psi and0 to 1,200 gallons/minute in order to optimally provide operationalefficiency.

[0604] At a predetermined point in the injection of the first fluidicmaterial such as, for example, after the annular region outside of theapparatus 2300 has been filled to a predetermined level, a plug 2470,dart, or other similar device is introduced into the first fluidicmaterial. The plug 2470 lodges in the throat passage 2465 therebyfluidicly isolating the fluid passage 2405 from the fluid passage 2415.

[0605] After placement of the plug 2470 in the throat passage 2465, asecond fluidic material is pumped into the fluid passage 2380 in orderto pressurize the pressure chamber 2475. The second fluidic material maycomprise any number of conventional commercially available materialssuch as, for example, water, drilling gases, drilling mud or lubricants.In a preferred embodiment, the second fluidic material comprises anon-hardenable fluidic material such as, for example, water, drillingmud or lubricant.

[0606] The second fluidic material may be pumped into the apparatus 2300at operating pressures and flow rates ranging, for example, from about 0to 4,500 psi and 0 to 4,500 gallons/minute. In a preferred embodiment,the second fluidic material is pumped into the apparatus 2300 atoperating pressures and flow rates ranging from about 0 to 3,500 psi and0 to 1,200 gallons/minute in order to optimally provide operationalefficiency.

[0607] The pressurization of the pressure chamber 2475 causes the uppersealing head 2335, outer sealing mandrel 2350, and expansion cone 2355to move in an axial direction. The pressurization of the pressurechamber 2475 also causes the hydraulic slips 2325 to expand in theradial direction and hold the casing 2375 in a substantially stationaryposition. Furthermore, as the expansion cone 2355 moves in the axialdirection, the expansion cone 2355 pulls the mandrel launcher 2480 anddrag blocks 2370 along, which sets the mechanical slips 2365 and stopsfurther axial movement of the mandrel launcher 2480 and casing 2375. Inthis manner, the axial movement of the expansion cone 2355 radiallyexpands the mandrel launcher 2480 and casing 2375.

[0608] Once the upper sealing head 2335, outer sealing mandrel 2350, andexpansion cone 2355 complete an axial stroke, the operating pressure ofthe second fluidic material is reduced. The reduction in the operatingpressure of the second fluidic material releases the hydraulic slips2325. The drill string 2305 is then raised. This causes the innersealing mandrel 2330, lower sealing head 2340, load mandrel 2345, andmechanical slip body 2360 to move upward. This unsets the mechanicalslips 2365 and permits the mechanical slips 2365 and drag blocks 2370 tobe moved within the mandrel launcher 2480 and casing 2375. When thelower sealing head 2340 contacts the upper sealing head 2335, the secondfluidic material is again pressurized and the radial expansion processcontinues. In this manner, the mandrel launcher 2480 and casing 2375 areradial expanded through repeated axial strokes of the upper sealing head2335, outer sealing mandrel 2350 and expansion cone 2355. Throughput theradial expansion process, the upper end of the casing 2375 is preferablymaintained in an overlapping relation with an existing section ofwellbore casing.

[0609] At the end of the radial expansion process, the upper end of thecasing 2375 is expanded into intimate contact with the inside surface ofthe lower end of the existing wellbore casing. In a preferredembodiment, the sealing members provided at the upper end of the casing2375 provide a fluidic seal between the outside surface of the upper endof the casing 2375 and the inside surface of the lower end of theexisting wellbore casing. In a preferred embodiment, the contactpressure between the casing 2375 and the existing section of wellborecasing ranges from about 400 to 10,000 psi in order to optimally providecontact pressure, activate the sealing members, and withstand typicaltensile and compressive loading conditions.

[0610] In a preferred embodiment, as the expansion cone 2355 nears theupper end of the casing 2375, the operating pressure of the secondfluidic material is reduced in order to minimize shock to the apparatus2300. In an alternative embodiment, the apparatus 2300 includes a shockabsorber for absorbing the shock created by the completion of the radialexpansion of the casing 2375.

[0611] In a preferred embodiment, the reduced operating pressure of thesecond fluidic material ranges from about 100 to 1,000 psi as theexpansion cone 2355 nears the end of the casing 2375 in order tooptimally provide reduced axial movement and velocity of the expansioncone 2355. In a preferred embodiment, the operating pressure of thesecond fluidic material is reduced during the return stroke of theapparatus 2300 to the range of about 0 to 500 psi in order minimize theresistance to the movement of the expansion cone 2355 during the returnstroke. In a preferred embodiment, the stroke length of the apparatus2300 ranges from about 10 to 45 feet in order to optimally provideequipment that can be handled by typical oil well rigging equipment andminimize the frequency at which the expansion cone 2355 must be stoppedto permit the apparatus 2300 to be re-stroked.

[0612] In an alternative embodiment, at least a portion of the uppersealing head 2335 includes an expansion cone for radially expanding themandrel launcher 2480 and casing 2375 during operation of the apparatus2300 in order to increase the surface area of the casing 2375 acted uponduring the radial expansion process. In this manner, the operatingpressures can be reduced.

[0613] In an alternative embodiment, mechanical slips 2365 arepositioned in an axial location between the sealing sleeve 2315 and theinner sealing mandrel 2330 in order to optimally the construction andoperation of the apparatus 2300.

[0614] Upon the complete radial expansion of the casing 2375, ifapplicable, the first fluidic material is permitted to cure within theannular region between the outside of the expanded casing 2375 and theinterior walls of the wellbore. In the case where the casing 2375 isslotted, the cured fluidic material preferably permeates and envelopsthe expanded casing 2375. In this manner, a new section of wellborecasing is formed within a wellbore. Alternatively, the apparatus 2300may be used to join a first section of pipeline to an existing sectionof pipeline. Alternatively, the apparatus 2300 may be used to directlyline the interior of a wellbore with a casing, without the use of anouter annular layer of a hardenable material. Alternatively, theapparatus 2300 may be used to expand a tubular support member in a hole.

[0615] During the radial expansion process, the pressurized areas of theapparatus 2300 are limited to the fluid passages 2380, 2385, 2390, 2395,2400, 2405, and 2410, and the pressure chamber 2475. No fluid pressureacts directly on the mandrel launcher 2480 and casing 2375. This permitsthe use of operating pressures higher than the mandrel launcher 2480 andcasing 2375 could normally withstand.

[0616] Referring now to FIG. 18, a preferred embodiment of an apparatus2500 for forming a mono-diameter wellbore casing will be described. Theapparatus 2500 preferably includes a drillpipe 2505, an innerstringadapter 2510, a sealing sleeve 2515, a hydraulic slip body 2520,hydraulic slips 2525, an inner sealing mandrel 2530, upper sealing head2535, lower sealing head 2540, outer sealing mandrel 2545, load mandrel2550, expansion cone 2555, casing 2560, and fluid passages 2565, 2570,2575, 2580, 2585, 2590, 2595, and 2600.

[0617] The drillpipe 2505 is coupled to the innerstring adapter 2510.During operation of the apparatus 2500, the drillpipe 2505 supports theapparatus 2500. The drillpipe 2505 preferably comprises a substantiallyhollow tubular member or members. The drillpipe 2505 may be fabricatedfrom any number of conventional commercially available materials suchas, for example, oilfield country tubular goods, low alloy steel, carbonsteel, stainless steel or other similar high strength materials. In apreferred embodiment, the drillpipe 2505 is fabricated from coiledtubing in order to faciliate the placement of the apparatus 2500 innon-vertical wellbores. The drillpipe 2505 may be coupled to theinnerstring adapter 2510 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, or a standard threaded connection. In a preferredembodiment, the drillpipe 2505 is removably coupled to the innerstringadapter 2510 by a drillpipe connection. a drillpipe connection providesthe advantages of high strength and easy disassembly.

[0618] The drillpipe 2505 preferably includes a fluid passage 2565 thatis adapted to convey fluidic materials from a surface location into thefluid passage 2570. In a preferred embodiment, the fluid passage 2565 isadapted to convey fluidic materials such as, for example, cement, epoxy,water, drilling mud, or lubricants at operating pressures and flow ratesranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute.

[0619] The innerstring adapter 2510 is coupled to the drill string 2505and the sealing sleeve 2515. The innerstring adapter 2510 preferablycomprises a substantially hollow tubular member or members. Theinnerstring adapter 2510 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the innerstring adapter 2510 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces.

[0620] The innerstring adapter 2510 may be coupled to the drill string2505 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, or a standard threadedconnection. In a preferred embodiment, the innerstring adapter 2510 isremovably coupled to the drill pipe 2505 by a drillpipe connection. Theinnerstring adapter 2510 may be coupled to the sealing sleeve 2515 usingany number of conventional commercially available mechanical couplingssuch as, for example, drillpipe connection, oilfield country tubulargoods specialty type threaded connection, ratchet-latch type threadedconnection or a standard threaded connection. In a preferred embodiment,the innerstring adapter 2510 is removably coupled to the sealing sleeve2515 by a standard threaded connection.

[0621] The innerstring adapter 2510 preferably includes a fluid passage2570 that is adapted to convey fluidic materials from the fluid passage2565 into the fluid passage 2575. In a preferred embodiment, the fluidpassage 2570 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0622] The sealing sleeve 2515 is coupled to the innerstring adapter2510 and the hydraulic slip body 2520. The sealing sleeve 2515preferably comprises a substantially hollow tubular member or members.The sealing sleeve 2515 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the sealing sleeve 2515 is fabricated from stainless steelin order to optimally provide high strength, corrosion resistance, andlow-friction surfaces.

[0623] The sealing sleeve 2515 may be coupled to the innerstring adapter2510 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connections, oilfield countrytubular goods specialty type threaded connection, ratchet-latch typethreaded connection, or a standard threaded connection. In a preferredembodiment, the sealing sleeve 2515 is removably coupled to theinnerstring adapter 2510 by a standard threaded connection. The sealingsleeve 2515 may be coupled to the hydraulic slip body 2520 using anynumber of conventional commercially available mechanical couplings suchas, for example, drillpipe connection, oilfield country tubular goodsspecialty type threaded connection, ratchet-latch type threadedconnection, or a standard threaded connection. In a preferredembodiment, the sealing sleeve 2515 is removably coupled to thehydraulic slip body 2520 by a standard threaded connection.

[0624] The sealing sleeve 2515 preferably includes a fluid passage 2575that is adapted to convey fluidic materials from the fluid passage 2570into the fluid passage 2580. In a preferred embodiment, the fluidpassage 2575 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0625] The hydraulic slip body 2520 is coupled to the sealing sleeve2515, the hydraulic slips 2525, and the inner sealing mandrel 2530. Thehydraulic slip body 2520 preferably comprises a substantially hollowtubular member or members. The hydraulic slip body 2520 may befabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, stainless steel or other similar highstrength materials. In a preferred embodiment, the hydraulic slip body2520 is fabricated from carbon steel in order to optimally provide highstrength.

[0626] The hydraulic slip body 2520 may be coupled to the sealing sleeve2515 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, ratchet-latch typethreaded connection or a standard threaded connection. In a preferredembodiment, the hydraulic slip body 2520 is removably coupled to thesealing sleeve 2515 by a standard threaded connection. The hydraulicslip body 2520 may be coupled to the slips 2525 using any number ofconventional commercially available mechanical couplings such as, forexample, threaded connection or welding. In a preferred embodiment, thehydraulic slip body 2520 is removably coupled to the slips 2525 by athreaded connection. The hydraulic slip body 2520 may be coupled to theinner sealing mandrel 2530 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, welding, amorphous bonding or a standard threadedconnection. In a preferred embodiment, the hydraulic slip body 2520 isremovably coupled to the inner sealing mandrel 2530 by a standardthreaded connection.

[0627] The hydraulic slips body 2520 preferably includes a fluid passage2580 that is adapted to convey fluidic materials from the fluid passage2575 into the fluid passage 2590. In a preferred embodiment, the fluidpassage 2580 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0628] The hydraulic slips body 2520 preferably includes fluid passages2585 that are adapted to convey fluidic materials from the fluid passage2580 into the pressure chambers of the hydraulic slips 2525. In thismanner, the slips 2525 are activated upon the pressurization of thefluid passage 2580 into contact with the inside surface of the casing2560. In a preferred embodiment, the fluid passages 2585 are adapted toconvey fluidic materials such as, for example, water, drilling mud orlubricants at operating pressures and flow rates ranging from about 0 to9,000 psi and 0 to 3,000 gallons/minute.

[0629] The slips 2525 are coupled to the outside surface of thehydraulic slip body 2520. During operation of the apparatus 2500, theslips 2525 are activated upon the pressurization of the fluid passage2580 into contact with the inside surface of the casing 2560. In thismanner, the slips 2525 maintain the casing 2560 in a substantiallystationary position.

[0630] The slips 2525 preferably include the fluid passages 2585, thepressure chambers 2605, spring bias 2610, and slip members 2615. Theslips 2525 may comprise any number of conventional commerciallyavailable hydraulic slips such as, for example, RTTS packer tungstencarbide hydraulic slips or Model 3L retrievable bridge plug withhydraulic slips. In a preferred embodiment, the slips 2525 comprise RTTSpacker tungsten carbide hydraulic slips available from HalliburtonEnergy Services in order to optimally provide resistance to axialmovement of the casing 2560 during the expansion process.

[0631] The inner sealing mandrel 2530 is coupled to the hydraulic slipbody 2520 and the lower sealing head 2540. The inner sealing mandrel2530 preferably comprises a substantially hollow tubular member ormembers. The inner sealing mandrel 2530 may be fabricated from anynumber of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel or other similar high strength materials. In a preferredembodiment, the inner sealing mandrel 2530 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces.

[0632] The inner sealing mandrel 2530 may be coupled to the hydraulicslip body 2520 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection,welding, amorphous bonding, or a standard threaded connection. In apreferred embodiment, the inner sealing mandrel 2530 is removablycoupled to the hydraulic slip body 2520 by a standard threadedconnection. The inner sealing mandrel 2530 may be coupled to the lowersealing head 2540 using any number of conventional commerciallyavailable mechanical couplings such as, for example, oilfield countrytubular goods specialty type threaded connection, drillpipe connection,welding, amorphous bonding, or a standard threaded connection. In apreferred embodiment, the inner sealing mandrel 2530 is removablycoupled to the lower sealing head 2540 by a standard threadedconnection.

[0633] The inner sealing mandrel 2530 preferably includes a fluidpassage 2590 that is adapted to convey fluidic materials from the fluidpassage 2580 into the fluid passage 2600. In a preferred embodiment, thefluid passage 2590 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0634] The upper sealing head 2535 is coupled to the outer sealingmandrel 2545 and expansion cone 2555. The upper sealing head 2535 isalso movably coupled to the outer surface of the inner sealing mandrel2530 and the inner surface of the casing 2560. In this manner, the uppersealing head 2535 reciprocates in the axial direction. The radialclearance between the inner cylindrical surface of the upper sealinghead 2535 and the outer surface of the inner sealing mandrel 2530 mayrange, for example, from about 0.0025 to 0.05 inches. In a preferredembodiment, the radial clearance between the inner cylindrical surfaceof the upper sealing head 2535 and the outer surface of the innersealing mandrel 2530 ranges from about 0.005 to 0.01 inches in order tooptimally provide minimal radial clearance. The radial clearance betweenthe outer cylindrical surface of the upper sealing head 2535 and theinner surface of the casing 2560 may range, for example, from about0.025 to 0.375 inches. In a preferred embodiment, the radial clearancebetween the outer cylindrical surface of the upper sealing head 2535 andthe inner surface of the casing 2560 ranges from about 0.025 to 0.125inches in order to optimally provide stabilization for the expansioncone 2535 during the expansion process.

[0635] The upper sealing head 2535 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Theupper sealing head 2535 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, ow alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the upper sealing head 2535 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces. The inner surface of the upper sealing head2535 preferably includes one or more annular sealing members 2620 forsealing the interface between the upper sealing head 2535 and the innersealing mandrel 2530. The sealing members 2620 may comprise any numberof conventional commercially available annular sealing members such as,for example, o-rings, polypak seals, or metal spring energized seals. Ina preferred embodiment, the sealing members 2620 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial stroke.

[0636] In a preferred embodiment, the upper sealing head 2535 includes ashoulder 2625 for supporting the upper sealing head 2535, outer sealingmandrel 2545, and expansion cone 2555 on the lower sealing head 2540.

[0637] The upper sealing head 2535 may be coupled to the outer sealingmandrel 2545 using any number of conventional commercially availablemechanical couplings such as, for example, oilfield country tubulargoods specialty threaded connection, pipeline connection, welding,amorphous bonding, or a standard threaded connection. In a preferredembodiment, the upper sealing head 2535 is removably coupled to theouter sealing mandrel 2545 by a standard threaded connection. In apreferred embodiment, the mechanical coupling between the upper sealinghead 2535 and the outer sealing mandrel 2545 includes one or moresealing members 2630 for fluidicly sealing the interface between theupper sealing head 2535 and the outer sealing mandrel 2545. The sealingmembers 2630 may comprise any number of conventional commerciallyavailable sealing members such as, for example, o-rings, polypak sealsor metal spring energized seals. In a preferred embodiment, the sealingmembers 2630 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for a long axial stroke.

[0638] The lower sealing head 2540 is coupled to the inner sealingmandrel 2530 and the load mandrel 2550. The lower sealing head 2540 isalso movably coupled to the inner surface of the outer sealing mandrel2545. In this manner, the upper sealing head 2535, outer sealing mandrel2545, and expansion cone 2555 reciprocate in the axial direction.

[0639] The radial clearance between the outer surface of the lowersealing head 2540 and the inner surface of the outer sealing mandrel2545 may range, for example, from about 0.0025 to 0.05 inches. In apreferred embodiment, the radial clearance between the outer surface ofthe lower sealing head 2540 and the inner surface of the outer sealingmandrel 2545 ranges from about 0.005 to 0.01 inches in order tooptimally provide minimal radial clearance.

[0640] The lower sealing head 2540 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Thelower sealing head 2540 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the lower sealing head 2540 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces. The outer surface of the lower sealing head2540 preferably includes one or more annular sealing members 2635 forsealing the interface between the lower sealing head 2540 and the outersealing mandrel 2545. The sealing members 2635 may comprise any numberof conventional commercially available annular sealing members such as,for example, o-rings, polypak seals, or metal spring energized seals. Ina preferred embodiment, the sealing members 2635 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial stroke.

[0641] The lower sealing head 2540 may be coupled to the inner sealingmandrel 2530 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connections,oilfield country tubular goods specialty threaded connection, or astandard threaded connection. In a preferred embodiment, the lowersealing head 2540 is removably coupled to the inner sealing mandrel 2530by a standard threaded connection. In a preferred embodiment, themechanical coupling between the lower sealing head 2540 and the innersealing mandrel 2530 includes one or more sealing members 2640 forfluidicly sealing the interface between the lower sealing head 2540 andthe inner sealing mandrel 2530. The sealing members 2640 may compriseany number of conventional commercially available sealing members suchas, for example, o-rings, polypak seals or metal spring energized seals.In a preferred embodiment, the sealing members 2640 comprise polypakseals available from Parker Seals in order to optimally provide sealingfor a long axial stroke.

[0642] The lower sealing head 2540 may be coupled to the load mandrel2550 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, welding, amorphousbonding or a standard threaded connection. In a preferred embodiment,the lower sealing head 2540 is removably coupled to the load mandrel2550 by a standard threaded connection. In a preferred embodiment, themechanical coupling between the lower sealing head 2540 and the loadmandrel 2550 includes one or more sealing members 2645 for fluidiclysealing the interface between the lower sealing head 2540 and the loadmandrel 2550. The sealing members 2645 may comprise any number ofconventional commercially available sealing members such as, forexample, o-rings, polypak seals or metal spring energized seals. In apreferred embodiment, the sealing members 2645 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial stroke.

[0643] In a preferred embodiment, the lower sealing head 2540 includes athroat passage 2650 fluidicly coupled between the fluid passages 2590and 2600. The throat passage 2650 is preferably of reduced size and isadapted to receive and engage with a plug 2655, or other similar device.In this manner, the fluid passage 2590 is fluidicly isolated from thefluid passage 2600. In this manner, the pressure chamber 2660 ispressurized.

[0644] The outer sealing mandrel 2545 is coupled to the upper sealinghead 2535 and the expansion cone 2555. The outer sealing mandrel 2545 isalso movably coupled to the inner surface of the casing 2560 and theouter surface of the lower sealing head 2540. In this manner, the uppersealing head 2535, outer sealing mandrel 2545, and the expansion cone2555 reciprocate in the axial direction. The radial clearance betweenthe outer surface of the outer sealing mandrel 2545 and the innersurface of the casing 2560 may range, for example, from about 0.025 to0.375 inches. In a preferred embodiment, the radial clearance betweenthe outer surface of the outer sealing mandrel 2545 and the innersurface of the casing 2560 ranges from about 0.025 to 0.125 inches inorder to optimally provide stabilization for the expansion cone 2535during the expansion process. The radial clearance between the innersurface of the outer sealing mandrel 2545 and the outer surface of thelower sealing head 2540 may range, for example, from about 0.005 to 0.01inches. In a preferred embodiment, the radial clearance between theinner surface of the outer sealing mandrel 2545 and the outer surface ofthe lower sealing head 2540 ranges from about 0.005 to 0.01 inches inorder to optimally provide minimal radial clearance.

[0645] The outer sealing mandrel 2545 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Theouter sealing mandrel 2545 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the outer sealing mandrel 2545 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces.

[0646] The outer sealing mandrel 2545 may be coupled to the uppersealing head 2535 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the outer sealing mandrel 2545 isremovably coupled to the upper sealing head 2535 by a standard threadedconnection. The outer sealing mandrel 2545 may be coupled to theexpansion cone 2555 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the outer sealing mandrel 2545 isremovably coupled to the expansion cone 2555 by a standard threadedconnection.

[0647] The upper sealing head 2535, the lower sealing head 2540, theinner sealing mandrel 2530, and the outer sealing mandrel 2545 togetherdefine a pressure chamber 2660. The pressure chamber 2660 is fluidiclycoupled to the passage 2590 via one or more passages 2595. Duringoperation of the apparatus 2500, the plug 2655 engages with the throatpassage 2650 to fluidicly isolate the fluid passage 2590 from the fluidpassage 2600. The pressure chamber 2660 is then pressurized which inturn causes the upper sealing head 2535, outer sealing mandrel 2545, andexpansion cone 2555 to reciprocate in the axial direction. The axialmotion of the expansion cone 2555 in turn expands the casing 2560 in theradial direction.

[0648] The load mandrel 2550 is coupled to the lower sealing head 2540.The load mandrel 2550 preferably comprises an annular member havingsubstantially cylindrical inner and outer surfaces. The load mandrel2550 may be fabricated from any number of conventional commerciallyavailable materials such as, for example, oilfield country tubulargoods, low alloy steel, carbon steel, stainless steel or other similarhigh strength materials. In a preferred embodiment, the load mandrel2550 is fabricated from stainless steel in order to optimally providehigh strength, corrosion resistance, and low friction surfaces.

[0649] The load mandrel 2550 may be coupled to the lower sealing head2540 using any number of conventional commercially available mechanicalcouplings such as, for example, oilfield country tubular goods,drillpipe connection, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the load mandrel 2550 isremovably coupled to the lower sealing head 2540 by a standard threadedconnection.

[0650] The load mandrel 2550 preferably includes a fluid passage 2600that is adapted to convey fluidic materials from the fluid passage 2590to the region outside of the apparatus 2500. In a preferred embodiment,the fluid passage 2600 is adapted to convey fluidic materials such as,for example, cement, epoxy, water, drilling mud, or lubricants atoperating pressures and flow rates ranging, for example, from about 0 to9,000 psi and 0 to 3,000 gallons/minute.

[0651] The expansion cone 2555 is coupled to the outer sealing mandrel2545. The expansion cone 2555 is also movably coupled to the innersurface of the casing 2560. In this manner, the upper sealing head 2535,outer sealing mandrel 2545, and the expansion cone 2555 reciprocate inthe axial direction. The reciprocation of the expansion cone 2555 causesthe casing 2560 to expand in the radial direction.

[0652] The expansion cone 2555 preferably comprises an annular memberhaving substantially cylindrical inner and conical outer surfaces. Theoutside radius of the outside conical surface may range, for example,from about 2 to 34 inches. In a preferred embodiment, the outside radiusof the outside conical surface ranges from about 3 to 28 in order tooptimally provide radial expansion for the widest variety of tubularcasings. The axial length of the expansion cone 2555 may range, forexample, from about 2 to 8 times the largest outside diameter of theexpansion cone 2535. In a preferred embodiment, the axial length of theexpansion cone 2535 ranges from about 3 to 5 times the largest outsidediameter of the expansion cone 2535 in order to optimally providestabilization and centralization of the expansion cone 2535 during theexpansion process. In a particularly preferred embodiment, the maximumoutside diameter of the expansion cone 2555 is between about 95 to 99%of the inside diameter of the existing wellbore that the casing 2560will be joined with. In a preferred embodiment, the angle of attack ofthe expansion cone 2555 ranges from about 5 to 30 degrees in order tooptimally balance frictional forces and radial expansion forces. Theoptimum angle of attack of the expansion cone 2535 will vary as afunction of the particular operational features of the expansionoperation.

[0653] The expansion cone 2555 may be fabricated from any number ofconventional commercially available materials such as, for example,machine tool steel, nitride steel, titanium, tungsten carbide, ceramicsor other similar high strength materials. In a preferred embodiment, theexpansion cone 2555 is fabricated from D2 machine tool steel in order tooptimally provide high strength, and resistance to wear and galling. Ina particularly preferred embodiment, the outside surface of theexpansion cone 2555 has a surface hardness ranging from about 58 to 62Rockwell C in order to optimally provide high strength and wearresistance.

[0654] The expansion cone 2555 may be coupled to the outside sealingmandrel 2545 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty threaded connection, welding,amorphous bonding or a standard threaded connection. In a preferredembodiment, the expansion cone 2555 is coupled to the outside sealingmandrel 2545 using a standard threaded connection in order to optimallyprovide high strength and easy replacement of the expansion cone 2555.

[0655] The casing 2560 is removably coupled to the slips 2525 andexpansion cone 2555. The casing 2560 preferably comprises a tubularmember. The casing 2560 may be fabricated from any number ofconventional commercially available materials such as, for example,slotted tubulars, oilfield country tubular goods, low alloy steel,carbon steel, stainless steel or other similar high strength materials.In a preferred embodiment, the casing 2560 is fabricated from oilfieldcountry tubular goods available from various foreign and domestic steelmills in order to optimally provide high strength using standardizedmaterials.

[0656] In a preferred embodiment, the upper end 2665 of the casing 2560includes a thin wall section 2670 and an outer annular sealing member2675. In a preferred embodiment, the wall thickness of the thin wallsection 2670 is about 50 to 100% of the regular wall thickness of thecasing 2560. In this manner, the upper end 2665 of the casing 2560 maybe easily radially expanded and deformed into intimate contact with thelower end of an existing section of wellbore casing. In a preferredembodiment, the lower end of the existing section of casing alsoincludes a thin wall section. In this manner, the radial expansion ofthe thin walled section 2670 of casing 2560 into the thin walled sectionof the existing wellbore casing results in a wellbore casing having asubstantially constant inside diameter.

[0657] The annular sealing member 2675 may be fabricated from any numberof conventional commercially available sealing materials such as, forexample, epoxy, rubber, metal, or plastic. In a preferred embodiment,the annular sealing member 2675 is fabricated from StrataLock epoxy inorder to optimally provide compressibility and resistance to wear. Theoutside diameter of the annular sealing member 2675 preferably rangesfrom about 70 to 95% of the inside diameter of the lower section of thewellbore casing that the casing 2560 is joined to. In this manner, afterradial expansion, the annular sealing member 2670 optimally provides afluidic seal and also preferably optimally provides sufficientfrictional force with the inside surface of the existing section ofwellbore casing during the radial expansion of the casing 2560 tosupport the casing 2560.

[0658] In a preferred embodiment, the lower end 2680 of the casing 2560includes a thin wall section 2685 and an outer annular sealing member2690. In a preferred embodiment, the wall thickness of the thin wallsection 2685 is about 50 to 100% of the regular wall thickness of thecasing 2560. In this manner, the lower end 2680 of the casing 2560 maybe easily expanded and deformed. Furthermore, in this manner, an othersection of casing may be easily joined with the lower end 2680 of thecasing 2560 using a radial expansion process. In a preferred embodiment,the upper end of the other section of casing also includes a thin wallsection. In this manner, the radial expansion of the thin walled sectionof the upper end of the other casing into the thin walled section 2685of the lower end 2680 of the casing 2560 results in a wellbore casinghaving a substantially constant inside diameter.

[0659] The annular sealing member 2690 may be fabricated from any numberof conventional commercially available sealing materials such as, forexample, rubber, metal, plastic or epoxy. In a preferred embodiment, theannular sealing member 2690 is fabricated from StrataLock epoxy in orderto optimally provide compressibility and resistance to wear. The outsidediameter of the annular sealing member 2690 preferably ranges from about70 to 95% of the inside diameter of the lower section of the existingwellbore casing that the casing 2560 is joined to. In this manner, afterradial expansion, the annular sealing member 2690 preferably provides afluidic seal and also preferably provides sufficient frictional forcewith the inside wall of the wellbore during the radial expansion of thecasing 2560 to support the casing 2560.

[0660] During operation, the apparatus 2500 is preferably positioned ina wellbore with the upper end 2665 of the casing 2560 positioned in anoverlapping relationship with the lower end of an existing wellborecasing. In a particularly preferred embodiment, the thin wall section2670 of the casing 2560 is positioned in opposing overlapping relationwith the thin wall section and outer annular sealing member of the lowerend of the existing section of wellbore casing. In this manner, theradial expansion of the casing 2560 will compress the thin wall sectionsand annular compressible members of the upper end 2665 of the casing2560 and the lower end of the existing wellbore casing into intimatecontact. During the positioning of the apparatus 2500 in the wellbore,the casing 2560 is supported by the expansion cone 2555.

[0661] After positioning of the apparatus 2500, a first fluidic materialis then pumped into the fluid passage 2565. The first fluidic materialmay comprise any number of conventional commercially available materialssuch as, for example, cement, water, slag-mix, epoxy or drilling mud. Ina preferred embodiment, the first fluidic material comprises ahardenable fluidic sealing material such as, for example, cement, epoxy,or slag-mix in order to optimally provide a hardenable outer annularbody around the expanded casing 2560.

[0662] The first fluidic material may be pumped into the fluid passage2565 at operating pressures and flow rates ranging, for example, fromabout 0 to 4,500 psi and 0 to 3,000 gallons/minute. In a preferredembodiment, the first fluidic material is pumped into the fluid passage2565 at operating pressures and flow rates ranging from about 0 to 3,500psi and 0 to 1,200 gallons/minute in order to optimally provideoperational efficiency.

[0663] The first fluidic material pumped into the fluid passage 2565passes through the fluid passages 2570, 2575, 2580, 2590, 2600 and thenoutside of the apparatus 2500. The first fluidic material thenpreferably fills the annular region between the outside of the apparatus2500 and the interior walls of the wellbore.

[0664] The plug 2655 is then introduced into the fluid passage 2565. Theplug 2655 lodges in the throat passage 2650 and fluidicly isolates andblocks off the fluid passage 2590. In a preferred embodiment, a coupleof volumes of a non-hardenable fluidic material are then pumped into thefluid passage 2565 in order to remove any hardenable fluidic materialcontained within and to ensure that none of the fluid passages areblocked.

[0665] A second fluidic material is then pumped into the fluid passage2565. The second fluidic material may comprise any number ofconventional commercially available materials such as, for example,water, drilling gases, drilling mud or lubricant. In a preferredembodiment, the second fluidic material comprises a non-hardenablefluidic material such as, for example, water, drilling mud, or lubricantin order to optimally provide pressurization of the pressure chamber2660 and minimize friction.

[0666] The second fluidic material may be pumped into the fluid passage2565 at operating pressures and flow rates ranging, for example, fromabout 0 to 4,500 psi and 0 to 4,500 gallons/minute. In a preferredembodiment, the second fluidic material is pumped into the fluid passage2565 at operating pressures and flow rates ranging from about 0 to 3,500psi and 0 to 1,200 gallons/minute in order to optimally provideoperational efficiency.

[0667] The second fluidic material pumped into the fluid passage 2565passes through the fluid passages 2570, 2575, 2580, 2590 and into thepressure chambers 2605 of the slips 2525, and into the pressure chamber2660. Continued pumping of the second fluidic material pressurizes thepressure chambers 2605 and 2660.

[0668] The pressurization of the pressure chambers 2605 causes the slipmembers 2525 to expand in the radial direction and grip the interiorsurface of the casing 2560. The casing 2560 is then preferablymaintained in a substantially stationary position.

[0669] The pressurization of the pressure chamber 2660 causes the uppersealing head 2535, outer sealing mandrel 2545 and expansion cone 2555 tomove in an axial direction relative to the casing 2560. In this manner,the expansion cone 2555 will cause the casing 2560 to expand in theradial direction, beginning with the lower end 2685 of the casing 2560.

[0670] During the radial expansion process, the casing 2560 is preventedfrom moving in an upward direction by the slips 2525. A length of thecasing 2560 is then expanded in the radial direction through thepressurization of the pressure chamber 2660. The length of the casing2560 that is expanded during the expansion process will be proportionalto the stroke length of the upper sealing head 2535, outer sealingmandrel 2545, and expansion cone 2555.

[0671] Upon the completion of a stroke, the operating pressure of thesecond fluidic material is reduced and the upper sealing head 2535,outer sealing mandrel 2545, and expansion cone 2555 drop to their restpositions with the casing 2560 supported by the expansion cone 2555. Theposition of the drillpipe 2505 is preferably adjusted throughout theradial expansion process in order to maintain the overlappingrelationship between the thin walled sections of the lower end of theexisting wellbore casing and the upper end of the casing 2560. In apreferred embodiment, the stroking of the expansion cone 2555 is thenrepeated, as necessary, until the thin walled section 2670 of the upperend 2665 of the casing 2560 is expanded into the thin walled section ofthe lower end of the existing wellbore casing. In this manner, awellbore casing is formed including two adjacent sections of casinghaving a substantially constant inside diameter. This process may thenbe repeated for the entirety of the wellbore to provide a wellborecasing thousands of feet in length having a substantially constantinside diameter.

[0672] In a preferred embodiment, during the final stroke of theexpansion cone 2555, the slips 2525 are positioned as close as possibleto the thin walled section 2670 of the upper end 2665 of the casing 2560in order minimize slippage between the casing 2560 and the existingwellbore casing at the end of the radial expansion process.Alternatively, or in addition, the outside diameter of the annularsealing member 2675 is selected to ensure sufficient interference fitwith the inside diameter of the lower end of the existing casing toprevent axial displacement of the casing 2560 during the final stroke.Alternatively, or in addition, the outside diameter of the annularsealing member 2690 is selected to provide an interference fit with theinside walls of the wellbore at an earlier point in the radial expansionprocess so as to prevent further axial displacement of the casing 2560.In this final alternative, the interference fit is preferably selectedto permit expansion of the casing 2560 by pulling the expansion cone2555 out of the wellbore, without having to pressurize the pressurechamber 2660.

[0673] During the radial expansion process, the pressurized areas of theapparatus 2500 are preferably limited to the fluid passages 2565, 2570,2575, 2580, and 2590, the pressure chambers 2605 within the slips 2525,and the pressure chamber 2660. No fluid pressure acts directly on thecasing 2560. This permits the use of operating pressures higher than thecasing 2560 could normally withstand.

[0674] Once the casing 2560 has been completely expanded off of theexpansion cone 2555, the remaining portions of the apparatus 2500 areremoved from the wellbore. In a preferred embodiment, the contactpressure between the deformed thin wall sections and compressibleannular members of the lower end of the existing casing and the upperend 2665 of the casing 2560 ranges from about 400 to 10,000 psi in orderto optimally support the casing 2560 using the existing wellbore casing.

[0675] In this manner, the casing 2560 is radially expanded into contactwith an existing section of casing by pressurizing the interior fluidpassages 2565, 2570, 2575, 2580, and 2590, the pressure chambers of theslips 2605 and the pressure chamber 2660 of the apparatus 2500.

[0676] In a preferred embodiment, as required, the annular body ofhardenable fluidic material is then allowed to cure to form a rigidouter annular body about the expanded casing 2560. In the case where thecasing 2560 is slotted, the cured fluidic material preferably permeatesand envelops the expanded casing 2560. The resulting new section ofwellbore casing includes the expanded casing 2560 and the rigid outerannular body. The overlapping joint between the pre-existing wellborecasing and the expanded casing 2560 includes the deformed thin wallsections and the compressible outer annular bodies. The inner diameterof the resulting combined wellbore casings is substantially constant. Inthis manner, a mono-diameter wellbore casing is formed. This process ofexpanding overlapping tubular members having thin wall end portions withcompressible annular bodies into contact can be repeated for the entirelength of a wellbore. In this manner, a mono-diameter wellbore casingcan be provided for thousands of feet in a subterranean formation.

[0677] In a preferred embodiment, as the expansion cone 2555 nears theupper end 2665 of the casing 2560, the operating pressure of the secondfluidic material is reduced in order to minimize shock to the apparatus2500. In an alternative embodiment, the apparatus 2500 includes a shockabsorber for absorbing the shock created by the completion of the radialexpansion of the casing 2560.

[0678] In a preferred embodiment, the reduced operating pressure of thesecond fluidic material ranges from about 100 to 1,000 psi as theexpansion cone 2555 nears the end of the casing 2560 in order tooptimally provide reduced axial movement and velocity of the expansioncone 2555. In a preferred embodiment, the operating pressure of thesecond fluidic material is reduced during the return stroke of theapparatus 2500 to the range of about 0 to 500 psi in order minimize theresistance to the movement of the expansion cone 2555 during the returnstroke. In a preferred embodiment, the stroke length of the apparatus2500 ranges from about 10 to 45 feet in order to optimally provideequipments lengths that can be easily handled using typical oil wellrigging equipment and also minimize the frequency at which apparatus2500 must be re-stroked.

[0679] In an alternative embodiment, at least a portion of the uppersealing head 2535 includes an expansion cone for radially expanding thecasing 2560 during operation of the apparatus 2500 in order to increasethe surface area of the casing 2560 acted upon during the radialexpansion process. In this manner, the operating pressures can bereduced.

[0680] Alternatively, the apparatus 2500 may be used to join a firstsection of pipeline to an existing section of pipeline. Alternatively,the apparatus 2500 may be used to directly line the interior of awellbore with a casing, without the use of an outer annular layer of ahardenable material. Alternatively, the apparatus 2500 may be used toexpand a tubular support member in a hole.

[0681] Referring now to FIGS. 19, 19a and 19 b, another embodiment of anapparatus 2700 for expanding a tubular member will be described. Theapparatus 2700 preferably includes a drillpipe 2705, an innerstringadapter 2710, a sealing sleeve 2715, a first inner sealing mandrel 2720,a first upper sealing head 2725, a first lower sealing head 2730, afirst outer sealing mandrel 2735, a second inner sealing mandrel 2740, asecond upper sealing head 2745, a second lower sealing head 2750, asecond outer sealing mandrel 2755, a load mandrel 2760, an expansioncone 2765, a mandrel launcher 2770, a mechanical slip body 2775,mechanical slips 2780, drag blocks 2785, casing 2790, and fluid passages2795, 2800, 2805, 2810, 2815, 2820, 2825, and 2830.

[0682] The drillpipe 2705 is coupled to the innerstring adapter 2710.During operation of the apparatus 2700, the drillpipe 2705 supports theapparatus 2700. The drillpipe 2705 preferably comprises a substantiallyhollow tubular member or members. The drillpipe 2705 may be fabricatedfrom any number of conventional commercially available materials suchas, for example, oilfield country tubular goods, low alloy steel, carbonsteel, stainless steel, or other similar high strength materials. In apreferred embodiment, the drillpipe 2705 is fabricated from coiledtubing in order to facilitate the placement of the apparatus 2700 innon-vertical wellbores. The drillpipe 2705 may be coupled to theinnerstring adapter 2710 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, or a standard threaded connection. In a preferredembodiment, the drillpipe 2705 is removably coupled to the innerstringadapter 2710 by a drillpipe connection in order to optimally providehigh strength and easy disassembly.

[0683] The drillpipe 2705 preferably includes a fluid passage 2795 thatis adapted to convey fluidic materials from a surface location into thefluid passage 2800. In a preferred embodiment, the fluid passage 2795 isadapted to convey fluidic materials such as, for example, cement, epoxy,water, drilling mud or lubricants at operating pressures and flow ratesranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute.

[0684] The innerstring adapter 2710 is coupled to the drill string 2705and the sealing sleeve 2715. The innerstring adapter 2710 preferablycomprises a substantially hollow tubular member or members. Theinnerstring adapter 2710 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the innerstring adapter 2710 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces.

[0685] The innerstring adapter 2710 may be coupled to the drill string2705 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty threaded connection, or a standard threadedconnection. In a preferred embodiment, the innerstring adapter 2710 isremovably coupled to the drill pipe 2705 by a standard threadedconnection in order to optimally provide high strength and easydisassembly. The innerstring adapter 2710 may be coupled to the sealingsleeve 2715 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection,ratchet-latch type threaded connection or a standard threadedconnection. In a preferred embodiment, the innerstring adapter 2710 isremovably coupled to the sealing sleeve 2715 by a standard threadedconnection.

[0686] The innerstring adapter 2710 preferably includes a fluid passage2800 that is adapted to convey fluidic materials from the fluid passage2795 into the fluid passage 2805. In a preferred embodiment, the fluidpassage 2800 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0687] The sealing sleeve 2715 is coupled to the innerstring adapter2710 and the first inner sealing mandrel 2720. The sealing sleeve 2715preferably comprises a substantially hollow tubular member or members.The sealing sleeve 2715 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the sealing sleeve 2715 is fabricated from stainless steelin order to optimally provide high strength, corrosion resistance, andlow friction surfaces.

[0688] The sealing sleeve 2715 may be coupled to the innerstring adapter2710 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, welding, amorphousbonding, or a standard threaded connection. In a preferred embodiment,the sealing sleeve 2715 is removably coupled to the innerstring adapter2710 by a standard threaded connector. The sealing sleeve 2715 may becoupled to the first inner sealing mandrel 2720 using any number ofconventional commercially available mechanical couplings such as, forexample, drillpipe connection, oilfield country tubular goods specialtytype threaded connection, welding, amorphous bonding or a standardthreaded connection. In a preferred embodiment, the sealing sleeve 2715is removably coupled to the inner sealing mandrel 2720 by a standardthreaded connection.

[0689] The sealing sleeve 2715 preferably includes a fluid passage 2802that is adapted to convey fluidic materials from the fluid passage 2800into the fluid passage 2805. In a preferred embodiment, the fluidpassage 2802 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0690] The first inner sealing mandrel 2720 is coupled to the sealingsleeve 2715 and the first lower sealing head 2730. The first innersealing mandrel 2720 preferably comprises a substantially hollow tubularmember or members. The first inner sealing mandrel 2720 may befabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, stainless steel or other similar highstrength materials. In a preferred embodiment, the first inner sealingmandrel 2720 is fabricated from stainless steel in order to optimallyprovide high strength, corrosion resistance, and low friction surfaces.

[0691] The first inner sealing mandrel 2720 may be coupled to thesealing sleeve 2715 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection oilfield country tubular goods specialty threaded connection,welding, amorphous bonding, or a standard threaded connection. In apreferred embodiment, the first inner sealing mandrel 2720 is removablycoupled to the sealing sleeve 2715 by a standard threaded connection.The first inner sealing mandrel 2720 may be coupled to the first lowersealing head 2730 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the first inner sealing mandrel2720 is removably coupled to the first lower sealing head 2730 by astandard threaded connection.

[0692] The first inner sealing mandrel 2720 preferably includes a fluidpassage 2805 that is adapted to convey fluidic materials from the fluidpassage 2802 into the fluid passage 2810. In a preferred embodiment, thefluid passage 2805 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0693] The first upper sealing head 2725 is coupled to the first outersealing mandrel 2735, the second upper sealing head 2745, the secondouter sealing mandrel 2755, and the expansion cone 2765. The first uppersealing head 2725 is also movably coupled to the outer surface of thefirst inner sealing mandrel 2720 and the inner surface of the casing2790. In this manner, the first upper sealing head 2725 reciprocates inthe axial direction. The radial clearance between the inner cylindricalsurface of the first upper sealing head 2725 and the outer surface ofthe first inner sealing mandrel 2720 may range, for example, from about0.0025 to 0.05 inches. In a preferred embodiment, the radial clearancebetween the inner cylindrical surface of the first upper sealing head2725 and the outer surface of the first inner sealing mandrel 2720ranges from about 0.005 to 0.125 inches in order to optimally provideminimal radial clearance. The radial clearance between the outercylindrical surface of the first upper sealing head 2725 and the innersurface of the casing 2790 may range, for example, from about 0.025 to0.375 inches. In a preferred embodiment, the radial clearance betweenthe outer cylindrical surface of the first upper sealing head 2725 andthe inner surface of the casing 2790 ranges from about 0.025 to 0.125inches in order to optimally provide stabilization for the expansioncone 2765 during the expansion process.

[0694] The first upper sealing head 2725 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Thefirst upper sealing head 2725 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the first upper sealing head 2725 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance and low friction surfaces. The inner surface of the firstupper sealing head 2725 preferably includes one or more annular sealingmembers 2835 for sealing the interface between the first upper sealinghead 2725 and the first inner sealing mandrel 2720. The sealing members2835 may comprise any number of conventional commercially availableannular sealing members such as, for example, o-rings, polypak seals ormetal spring energized seals. In a preferred embodiment, the sealingmembers 2835 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for long axial strokes.

[0695] In a preferred embodiment, the first upper sealing head 2725includes a shoulder 2840 for supporting the first upper sealing head2725 on the first lower sealing head 2730.

[0696] The first upper sealing head 2725 may be coupled to the firstouter sealing mandrel 2735 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, welding, amorphous bonding or a standard threadedconnection. In a preferred embodiment, the first upper sealing head 2725is removably coupled to the first outer sealing mandrel 2735 by astandard threaded connection. In a preferred embodiment, the mechanicalcoupling between the first upper sealing head 2725 and the first outersealing mandrel 2735 includes one or more sealing members 2845 forfluidicly sealing the interface between the first upper sealing head2725 and the first outer sealing mandrel 2735. The sealing members 2845may comprise any number of conventional commercially available sealingmembers such as, for example, o-rings, polypak seals or metal springenergized seals. In a preferred embodiment, the sealing members 2845comprise polypak seals available from Parker Seals in order to optimallyprovide sealing for long axial strokes.

[0697] The first lower sealing head 2730 is coupled to the first innersealing mandrel 2720 and the second inner sealing mandrel 2740. Thefirst lower sealing head 2730 is also movably coupled to the innersurface of the first outer sealing mandrel 2735. In this manner, thefirst upper sealing head 2725 and first outer sealing mandrel 2735reciprocate in the axial direction. The radial clearance between theouter surface of the first lower sealing head 2730 and the inner surfaceof the first outer sealing mandrel 2735 may range, for example, fromabout 0.0025 to 0.05 inches. In a preferred embodiment, the radialclearance between the outer surface of the first lower sealing head 2730and the inner surface of the first outer sealing mandrel 2735 rangesfrom about 0.005 to 0.01 inches in order to optimally provide minimalradial clearance.

[0698] The first lower sealing head 2730 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Thefirst lower sealing head 2730 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the first lower sealing head 2730 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance, and low friction surfaces. The outer surface of the firstlower sealing head 2730 preferably includes one or more annular sealingmembers 2850 for sealing the interface between the first lower sealinghead 2730 and the first outer sealing mandrel 2735. The sealing members2850 may comprise any number of conventional commercially availableannular sealing members such as, for example, o-rings, polypak seals ormetal spring energized seals. In a preferred embodiment, the sealingmembers 2850 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for long axial strokes.

[0699] The first lower sealing head 2730 may be coupled to the firstinner sealing mandrel 2720 using any number of conventional commerciallyavailable mechanical couplings such as, for example, oilfield countrytubular goods specialty threaded connections, welding, amorphousbonding, or standard threaded connection. In a preferred embodiment, thefirst lower sealing head 2730 is removably coupled to the first innersealing mandrel 2720 by a standard threaded connection. In a preferredembodiment, the mechanical coupling between the first lower sealing head2730 and the first inner sealing mandrel 2720 includes one or moresealing members 2855 for fluidicly sealing the interface between thefirst lower sealing head 2730 and the first inner sealing mandrel 2720.The sealing members 2855 may comprise any number of conventionalcommercially available sealing members such as, for example, o-rings,polypak seals or metal spring energized seals. In a preferredembodiment, the sealing members 2855 comprise polypak seals availablefrom Parker Seals in order to optimally provide sealing for long axialstrokes.

[0700] The first lower sealing head 2730 may be coupled to the secondinner sealing mandrel 2740 using any number of conventional commerciallyavailable mechanical couplings such as, for example, oilfield countrytubular goods specialty threaded connection, welding, amorphous bonding,or a standard threaded connection. In a preferred embodiment, the lowersealing head 2730 is removably coupled to the second inner sealingmandrel 2740 by a standard threaded connection. In a preferredembodiment, the mechanical coupling between the first lower sealing head2730 and the second inner sealing mandrel 2740 includes one or moresealing members 2860 for fluidicly sealing the interface between thefirst lower sealing head 2730 and the second inner sealing mandrel 2740.The sealing members 2860 may comprise any number of conventionalcommercially available sealing members such as, for example, o-rings,polypak seals or metal spring energized seals. In a preferredembodiment, the sealing members 2860 comprise polypak seals availablefrom Parker Seals in order to optimally provide sealing for long axialstrokes.

[0701] The first outer sealing mandrel 2735 is coupled to the firstupper sealing head 2725, the second upper sealing head 2745, the secondouter sealing mandrel 2755, and the expansion cone 2765. The first outersealing mandrel 2735 is also movably coupled to the inner surface of thecasing 2790 and the outer surface of the first lower sealing head 2730.In this manner, the first upper sealing head 2725, first outer sealingmandrel 2735, second upper sealing head 2745, second outer sealingmandrel 2755, and the expansion cone 2765 reciprocate in the axialdirection. The radial clearance between the outer surface of the firstouter sealing mandrel 2735 and the inner surface of the casing 2790 mayrange, for example, from about 0.025 to 0.375 inches. In a preferredembodiment, the radial clearance between the outer surface of the firstouter sealing mandrel 2735 and the inner surface of the casing 2790ranges from about 0.025 to 0.125 inches in order to optimally providestabilization for the expansion cone 2765 during the expansion process.The radial clearance between the inner surface of the first outersealing mandrel 2735 and the outer surface of the first lower sealinghead 2730 may range, for example, from about 0.0025 to 0.05 inches. In apreferred embodiment, the radial clearance between the inner surface ofthe first outer sealing mandrel 2735 and the outer surface of the firstlower sealing head 2730 ranges from about 0.005 to 0.01 inches in orderto optimally provide minimal radial clearance.

[0702] The outer sealing mandrel 1935 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Thefirst outer sealing mandrel 2735 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the first outer sealing mandrel 2735 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance, and low friction surfaces.

[0703] The first outer sealing mandrel 2735 may be coupled to the firstupper sealing head 2725 using any number of conventional commerciallyavailable mechanical couplings such as, for example, oilfield countrytubular goods, welding, amorphous bonding, or a standard threadedconnection. In a preferred embodiment, the first outer sealing mandrel2735 is removably coupled to the first upper sealing head 2725 by astandard threaded connection. The first outer sealing mandrel 2735 maybe coupled to the second upper sealing head 2745 using any number ofconventional commercially available mechanical couplings such as, forexample, oilfield country tubular goods specialty threaded connection,welding, amorphous bonding, or a standard threaded connection. In apreferred embodiment, the first outer sealing mandrel 2735 is removablycoupled to the second upper sealing head 2745 by a standard threadedconnection.

[0704] The second inner sealing mandrel 2740 is coupled to the firstlower sealing head 2730 and the second lower sealing head 2750. Thesecond inner sealing mandrel 2740 preferably comprises a substantiallyhollow tubular member or members. The second inner sealing mandrel 2740may be fabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, stainless steel or other similar highstrength materials. In a preferred embodiment, the second inner sealingmandrel 2740 is fabricated from stainless steel in order to optimallyprovide high strength, corrosion resistance, and low friction surfaces.

[0705] The second inner sealing mandrel 2740 may be coupled to the firstlower sealing head 2730 using any number of conventional commerciallyavailable mechanical couplings such as, for example, oilfield countrytubular goods specialty threaded connection, welding, amorphous bonding,or a standard threaded connection. In a preferred embodiment, the secondinner sealing mandrel 2740 is removably coupled to the first lowersealing head 2740 by a standard threaded connection. The mechanicalcoupling between the second inner sealing mandrel 2740 and the firstlower sealing head 2730 preferably includes sealing members 2860.

[0706] The second inner sealing mandrel 2740 may be coupled to thesecond lower sealing head 2750 using any number of conventionalcommercially available mechanical couplings such as, for example,oilfield country tubular goods specialty threaded connection, welding,amorphous bonding, or a standard threaded connection. In a preferredembodiment, the second inner sealing mandrel 2720 is removably coupledto the second lower sealing head 2750 by a standard threaded connection.In a preferred embodiment, the mechanical coupling between the secondinner sealing mandrel 2740 and the second lower sealing head 2750includes one or more sealing members 2865. The sealing members 2865 maycomprise any number of conventional commercially available seals suchas, for example, o-rings, polypak seals or metal spring energized seals.In a preferred embodiment, the sealing members 2865 comprise polypakseals available from Parker Seals.

[0707] The second inner sealing mandrel 2740 preferably includes a fluidpassage 2810 that is adapted to convey fluidic materials from the fluidpassage 2805 into the fluid passage 2815. In a preferred embodiment, thefluid passage 2810 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0708] The second upper sealing head 2745 is coupled to the first uppersealing head 2725, the first outer sealing mandrel 2735, the secondouter sealing mandrel 2755, and the expansion cone 2765. The secondupper sealing head 2745 is also movably coupled to the outer surface ofthe second inner sealing mandrel 2740 and the inner surface of thecasing 2790. In this manner, the second upper sealing head 2745reciprocates in the axial direction. The radial clearance between theinner cylindrical surface of the second upper sealing head 2745 and theouter surface of the second inner sealing mandrel 2740 may range, forexample, from about 0.0025 to 0.05 inches. In a preferred embodiment,the radial clearance between the inner cylindrical surface of the secondupper sealing head 2745 and the outer surface of the second innersealing mandrel 2740 ranges from about 0.005 to 0.01 inches in order tooptimally provide minimal radial clearance. The radial clearance betweenthe outer cylindrical surface of the second upper sealing head 2745 andthe inner surface of the casing 2790 may range, for example, from about0.025 to 0.375 inches. In a preferred embodiment, the radial clearancebetween the outer cylindrical surface of the second upper sealing head2745 and the inner surface of the casing 2790 ranges from about 0.025 to0.125 inches in order to optimally provide stabilization for theexpansion cone 2765 during the expansion process.

[0709] The second upper sealing head 2745 preferably comprises anannular member having substantially cylindrical inner and outersurfaces. The second upper sealing head 2745 may be fabricated from anynumber of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel or other similar high strength materials. In a preferredembodiment, the second upper sealing head 2745 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance, and low friction surfaces. The inner surface of the secondupper sealing head 2745 preferably includes one or more annular sealingmembers 2870 for sealing the interface between the second upper sealinghead 2745 and the second inner sealing mandrel 2740. The sealing members2870 may comprise any number of conventional commercially availableannular sealing members such as, for example, o-rings, polypak seals, ormetal spring energized seals. In a preferred embodiment, the sealingmembers 2870 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for long axial strokes.

[0710] In a preferred embodiment, the second upper sealing head 2745includes a shoulder 2875 for supporting the second upper sealing head2745 on the second lower sealing head 2750.

[0711] The second upper sealing head 2745 may be coupled to the firstouter sealing mandrel 2735 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, ratchet-latch type threaded connection, or a standardthreaded connection. In a preferred embodiment, the second upper sealinghead 2745 is removably coupled to the first outer sealing mandrel 2735by a standard threaded connection. In a preferred embodiment, themechanical coupling between the second upper sealing head 2745 and thefirst outer sealing mandrel 2735 includes one or more sealing members2880 for fluidicly sealing the interface between the second uppersealing head 2745 and the first outer sealing mandrel 2735. The sealingmembers 2880 may comprise any number of conventional commerciallyavailable sealing members such as, for example, o-rings, polypak sealsor metal spring energized seals. In a preferred embodiment, the sealingmembers 2880 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for a long axial stroke.

[0712] The second upper sealing head 2745 may be coupled to the secondouter sealing mandrel 2755 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, or a standard threaded connection. In a preferredembodiment, the second upper sealing head 2745 is removably coupled tothe second outer sealing mandrel 2755 by a standard threaded connection.In a preferred embodiment, the mechanical coupling between the secondupper sealing head 2745 and the second outer sealing mandrel 2755includes one or more sealing members 2885 for fluidicly sealing theinterface between the second upper sealing head 2745 and the secondouter sealing mandrel 2755. The sealing members 2885 may comprise anynumber of conventional commercially available sealing members such as,for example, o-rings, polypak seals or metal spring energized seals. Ina preferred embodiment, the sealing members 2885 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing forlong axial strokes.

[0713] The second lower sealing head 2750 is coupled to the second innersealing mandrel 2740 and the load mandrel 2760. The second lower sealinghead 2750 is also movably coupled to the inner surface of the secondouter sealing mandrel 2755. In this manner, the first upper sealing head2725, the first outer sealing mandrel 2735, second upper sealing head2745, second outer sealing mandrel 2755, and the expansion cone 2765reciprocate in the axial direction. The radial clearance between theouter surface of the second lower sealing head 2750 and the innersurface of the second outer sealing mandrel 2755 may range, for example,from about 0.0025 to 0.05 inches. In a preferred embodiment, the radialclearance between the outer surface of the second lower sealing head2750 and the inner surface of the second outer sealing mandrel 2755ranges from about 0.005 to 0.01 inches in order to optimally provideminimal radial clearance.

[0714] The second lower sealing head 2750 preferably comprises anannular member having substantially cylindrical inner and outersurfaces. The second lower sealing head 2750 may be fabricated from anynumber of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel or other similar high strength materials. In a preferredembodiment, the second lower sealing head 2750 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance, and low friction surfaces. The outer surface of the secondlower sealing head 2750 preferably includes one or more annular sealingmembers 2890 for sealing the interface between the second lower sealinghead 2750 and the second outer sealing mandrel 2755. The sealing members2890 may comprise any number of conventional commercially availableannular sealing members such as, for example, o-rings, polypak seals ormetal spring energized seals. In a preferred embodiment, the sealingmembers 2890 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for long axial strokes.

[0715] The second lower sealing head 2750 may be coupled to the secondinner sealing mandrel 2740 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, ratchet-latch type threaded connection, or a standardthreaded connection. In a preferred embodiment, the second lower sealinghead 2750 is removably coupled to the second inner sealing mandrel 2740by a standard threaded connection. In a preferred embodiment, themechanical coupling between the second lower sealing head 2750 and thesecond inner sealing mandrel 2740 includes one or more sealing members2895 for fluidicly sealing the interface between the second sealing head2750 and the second sealing mandrel 2740. The sealing members 2895 maycomprise any number of conventional commercially available sealingmembers such as, for example, o-rings, polypak seals or metal springenergized seals. In a preferred embodiment, the sealing members 2895comprise polypak seals available from Parker Seals in order to optimallyprovide sealing for a long axial stroke.

[0716] The second lower sealing head 2750 may be coupled to the loadmandrel 2760 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield tubular goods specialty threaded connection, ratchet-latch typethreaded connection, or a standard threaded connection. In a preferredembodiment, the second lower sealing head 2750 is removably coupled tothe load mandrel 2760 by a standard threaded connection. In a preferredembodiment, the mechanical coupling between the second lower sealinghead 2750 and the load mandrel 2760 includes one or more sealing members2900 for fluidicly sealing the interface between the second lowersealing head 2750 and the load mandrel 2760. The sealing members 2900may comprise any number of conventional commercially available sealingmembers such as, for example, o-rings, polypak seals or metal springenergized seals. In a preferred embodiment, the sealing members 2900comprise polypak seals available from Parker Seals in order to optimallyprovide sealing for long axial strokes.

[0717] In a preferred embodiment, the second lower sealing head 2750includes a throat passage 2905 fluidicly coupled between the fluidpassages 2810 and 2815. The throat passage 2905 is preferably of reducedsize and is adapted to receive and engage with a plug 2910, or othersimilar device. In this manner, the fluid passage 2810 is fluidiclyisolated from the fluid passage 2815. In this manner, the pressurechambers 2915 and 2920 are pressurized. The use of a plurality ofpressure chambers in the apparatus 2700 permits the effective drivingforce to be multiplied. While illustrated using a pair of pressurechambers, 2915 and 2920, the apparatus 2700 may be further modified toemploy additional pressure chambers.

[0718] The second outer sealing mandrel 2755 is coupled to the firstupper sealing head 2725, the first outer sealing mandrel 2735, thesecond upper sealing head 2745, and the expansion cone 2765. The secondouter sealing mandrel 2755 is also movably coupled to the inner surfaceof the casing 2790 and the outer surface of the second lower sealinghead 2750. In this manner, the first upper sealing head 2725, firstouter sealing mandrel 2735, second upper sealing head 2745, second outersealing mandrel 2755, and the expansion cone 2765 reciprocate in theaxial direction.

[0719] The radial clearance between the outer surface of the secondouter sealing mandrel 2755 and the inner surface of the casing 2790 mayrange, for example, from about 0.025 to 0.375 inches. In a preferredembodiment, the radial clearance between the outer surface of the secondouter sealing mandrel 2755 and the inner surface of the casing 2790ranges from about 0.025 to 0.125 inches in order to optimally providestabilization for the expansion cone 2765 during the expansion process.The radial clearance between the inner surface of the second outersealing mandrel 2755 and the outer surface of the second lower sealinghead 2750 may range, for example, from about 0.0025 to 0.05 inches. In apreferred embodiment, the radial clearance between the inner surface ofthe second outer sealing mandrel 2755 and the outer surface of thesecond lower sealing head 2750 ranges from about 0.005 to 0.01 inches inorder to optimally provide minimal radial clearance.

[0720] The second outer sealing mandrel 2755 preferably comprises anannular member having substantially cylindrical inner and outersurfaces. The second outer sealing mandrel 2755 may be fabricated fromany number of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel or other similar high strength materials. In a preferredembodiment, the second outer sealing mandrel 2755 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance, and low friction surfaces.

[0721] The second outer sealing mandrel 2755 may be coupled to thesecond upper sealing head 2745 using any number of conventionalcommercially available mechanical couplings such as, for example,drillpipe connection, oilfield country tubular goods specialty threadedconnection, ratchet-latch type threaded connection or a standardthreaded connection. In a preferred embodiment, the second outer sealingmandrel 2755 is removably coupled to the second upper sealing head 2745by a standard threaded connection. The second outer sealing mandrel 2755may be coupled to the expansion cone 2765 using any number ofconventional commercially available mechanical couplings such as, forexample, drillpipe connection, oilfield country tubular goods specialtytype threaded connection, ratchet-latch type threaded connection, or astandard threaded connection. In a preferred embodiment, the secondouter sealing mandrel 2755 is removably coupled to the expansion cone2765 by a standard threaded connection.

[0722] The load mandrel 2760 is coupled to the second lower sealing head2750 and the mechanical slip body 2755. The load mandrel 2760 preferablycomprises an annular member having substantially cylindrical inner andouter surfaces. The load mandrel 2760 may be fabricated from any numberof conventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the load mandrel 2760 is fabricated from stainless steel inorder to optimally provide high strength, corrosion resistance, and lowfriction surfaces.

[0723] The load mandrel 2760 may be coupled to the second lower sealinghead 2750 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection,ratchet-latch type threaded connection, or a standard threadedconnection. In a preferred embodiment, the load mandrel 2760 isremovably coupled to the second lower sealing head 2750 by a standardthreaded connection. The load mandrel 2760 may be coupled to themechanical slip body 2775 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection or a standardthreaded connection. In a preferred embodiment, the load mandrel 2760 isremovably coupled to the mechanical slip body 2775 by a standardthreaded connection.

[0724] The load mandrel 2760 preferably includes a fluid passage 2815that is adapted to convey fluidic materials from the fluid passage 2810to the fluid passage 2820. In a preferred embodiment, the fluid passage2815 is adapted to convey fluidic materials such as, for example,cement, epoxy, water, drilling mud or lubricants at operating pressuresand flow rates ranging from about 0 to 9,000 psi and 0 to 3,000gallons/minute.

[0725] The expansion cone 2765 is coupled to the second outer sealingmandrel 2755. The expansion cone 2765 is also movably coupled to theinner surface of the casing 2790. In this manner, the first uppersealing head 2725, first outer sealing mandrel 2735, second uppersealing head 2745, second outer sealing mandrel 2755, and the expansioncone 2765 reciprocate in the axial direction. The reciprocation of theexpansion cone 2765 causes the casing 2790 to expand in the radialdirection.

[0726] The expansion cone 2765 preferably comprises an annular memberhaving substantially cylindrical inner and conical outer surfaces. Theoutside radius of the outside conical surface may range, for example,from about 2 to 34 inches. In a preferred embodiment, the outside radiusof the outside conical surface ranges from about 3 to 28 inches in orderto optimally provide expansion cone dimensions that accommodate thetypical range of casings. The axial length of the expansion cone 2765may range, for example, from about 2 to 8 times the largest outerdiameter of the expansion cone 2765. In a preferred embodiment, theaxial length of the expansion cone 2765 ranges from about 3 to 5 timesthe largest outer diameter of the expansion cone 2765 in order tooptimally provide stabilization and centralization of the expansion cone2765. In a preferred embodiment, the angle of attack of the expansioncone 2765 ranges from about 5 to 30 degrees in order to optimallybalance frictional forces and radial expansion forces.

[0727] The expansion cone 2765 may be fabricated from any number ofconventional commercially available materials such as, for example,machine tool steel, nitride steel, titanium, tungsten carbide, ceramicsor other similar high strength materials. In a preferred embodiment, theexpansion cone 2765 is fabricated from D2 machine tool steel in order tooptimally provide high strength and resistance to corrosion and galling.In a particularly preferred embodiment, the outside surface of theexpansion cone 2765 has a surface hardness ranging from about 58 to 62Rockwell C in order to optimally provide high strength and resistance towear and galling.

[0728] The expansion cone 2765 may be coupled to the second outsidesealing mandrel 2765 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection or a standardthreaded connection. In a preferred embodiment, the expansion cone 2765is coupled to the second outside sealing mandrel 2765 using a standardthreaded connection in order to optimally provide high strength and easyreplacement of the expansion cone 2765.

[0729] The mandrel launcher 2770 is coupled to the casing 2790. Themandrel launcher 2770 comprises a tubular section of casing having areduced wall thickness compared to the casing 2790. In a preferredembodiment, the wall thickness of the mandrel launcher 2770 is about 50to 100% of the wall thickness of the casing 2790. The wall thickness ofthe mandrel launcher 2770 may range, for example, from about 0.15 to 1.5inches. In a preferred embodiment, the wall thickness of the mandrellauncher 2770 ranges from about 0.25 to 0.75 inches. In this manner, theinitiation of the radial expansion of the casing 2790 is facilitated,the placement of the apparatus 2700 within a wellbore casing andwellbore is facilitated, and the mandrel launcher 2770 has a burststrength approximately equal to that of the casing 2790.

[0730] The mandrel launcher 2770 may be coupled to the casing 2790 usingany number of conventional mechanical couplings such as, for example, astandard threaded connection. The mandrel launcher 2770 may befabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, stainless steel, or other similar highstrength materials. In a preferred embodiment, the mandrel launcher 2770is fabricated from oilfield country tubular goods of higher strengththan that of the casing 2790 but with a reduced wall thickness in orderto optimally provide a small compact tubular container having a burststrength approximately equal to that of the casing 2790.

[0731] The mechanical slip body 2775 is coupled to the load mandrel2760, the mechanical slips 2780, and the drag blocks 2785. Themechanical slip body 2775 preferably comprises a tubular member havingan inner passage 2820 fluidicly coupled to the passage 2815. In thismanner, fluidic materials may be conveyed from the passage 2820 to aregion outside of the apparatus 2700.

[0732] The mechanical slip body 2775 may be coupled to the load mandrel2760 using any number of conventional mechanical couplings. In apreferred embodiment, the mechanical slip body 2775 is removably coupledto the load mandrel 2760 using a standard threaded connection in orderto optimally provide high strength and easy disassembly. The mechanicalslip body 2775 may be coupled to the mechanical slips 2780 using anynumber of conventional mechanical couplings. In a preferred embodiment,the mechanical slip body 2755 is removably coupled to the mechanicalslips 2780 using threaded connections and sliding steel retainer ringsin order to optimally provide a high strength attachment. The mechanicalslip body 2755 may be coupled to the drag blocks 2785 using any numberof conventional mechanical couplings. In a preferred embodiment, themechanical slip body 2775 is removably coupled to the drag blocks 2785using threaded connections and sliding steel retainer rings in order tooptimally provide a high strength attachment.

[0733] The mechanical slip body 2775 preferably includes a fluid passage2820 that is adapted to convey fluidic materials from the fluid passage2815 to the region outside of the apparatus 2700. In a preferredembodiment, the fluid passage 2820 is adapted to convey fluidicmaterials such as, for example, cement, epoxy, water, drilling mud orlubricants at operating pressures and flow rates ranging from about 0 to9,000 psi and 0 to 3,000 gallons/minute.

[0734] The mechanical slips 2780 are coupled to the outside surface ofthe mechanical slip body 2775. During operation of the apparatus 2700,the mechanical slips 2780 prevent upward movement of the casing 2790 andmandrel launcher 2770. In this manner, during the axial reciprocation ofthe expansion cone 2765, the casing 2790 and mandrel launcher 2770 aremaintained in a substantially stationary position. In this manner, themandrel launcher 2765 and casing 2790 and mandrel launcher 2770 areexpanded in the radial direction by the axial movement of the expansioncone 2765.

[0735] The mechanical slips 2780 may comprise any number of conventionalcommercially available mechanical slips such as, for example, RTTSpacker tungsten carbide mechanical slips, RTTS packer wicker typemechanical slips or Model 3L retrievable bridge plug tungsten carbideupper mechanical slips. In a preferred embodiment, the mechanical slips2780 comprise RTTS packer tungsten carbide mechanical slips availablefrom Halliburton Energy Services in order to optimally provideresistance to axial movement of the casing 2790 and mandrel launcher2770 during the expansion process.

[0736] The drag blocks 2785 are coupled to the outside surface of themechanical slip body 2775. During operation of the apparatus 2700, thedrag blocks 2785 prevent upward movement of the casing 2790 and mandrellauncher 2770. In this manner, during the axial reciprocation of theexpansion cone 2765, the casing 2790 and mandrel launcher 2770 aremaintained in a substantially stationary position. In this manner, themandrel launcher 2770 and casing 2790 are expanded in the radialdirection by the axial movement of the expansion cone 2765.

[0737] The drag blocks 2785 may comprise any number of conventionalcommercially available mechanical slips such as, for example, RTTSpacker mechanical drag blocks or Model 3L retrievable bridge plug dragblocks. In a preferred embodiment, the drag blocks 2785 comprise RTTSpacker mechanical drag blocks available from Halliburton Energy Servicesin order to optimally provide resistance to axial movement of the casing2790 and mandrel launcher 2770 during the expansion process.

[0738] The casing 2790 is coupled to the mandrel launcher 2770. Thecasing 2790 is further removably coupled to the mechanical slips 2780and drag blocks 2785. The casing 2790 preferably comprises a tubularmember. The casing 2790 may be fabricated from any number ofconventional commercially available materials such as, for example,slotted tubulars, oilfield country tubular goods, low alloy steel,carbon steel, stainless steel or other similar high strength materials.In a preferred embodiment, the casing 2790 is fabricated from oilfieldcountry tubular goods available from various foreign and domestic steelmills in order to optimally provide high strength using standardizedmaterials. In a preferred embodiment, the upper end of the casing 2790includes one or more sealing members positioned about the exterior ofthe casing 2790.

[0739] During operation, the apparatus 2700 is positioned in a wellborewith the upper end of the casing 2790 positioned in an overlappingrelationship within an existing wellbore casing. In order minimize surgepressures within the borehole during placement of the apparatus 2700,the fluid passage 2795 is preferably provided with one or more pressurerelief passages. During the placement of the apparatus 2700 in thewellbore, the casing 2790 is supported by the expansion cone 2765.

[0740] After positioning of the apparatus 2700 within the bore hole inan overlapping relationship with an existing section of wellbore casing,a first fluidic material is pumped into the fluid passage 2795 from asurface location. The first fluidic material is conveyed from the fluidpassage 2795 to the fluid passages 2800, 2802, 2805, 2810, 2815, and2820. The first fluidic material will then exit the apparatus 2700 andfill the annular region between the outside of the apparatus 2700 andthe interior walls of the bore hole.

[0741] The first fluidic material may comprise any number ofconventional commercially available materials such as, for example,epoxy, drilling mud, slag mix, water or cement. In a preferredembodiment, the first fluidic material comprises a hardenable fluidicsealing material such as, for example, slag mix, epoxy, or cement. Inthis manner, a wellbore casing having an outer annular layer of ahardenable material may be formed.

[0742] The first fluidic material may be pumped into the apparatus 2700at operating pressures and flow rates ranging, for example, from about 0to 4,500 psi and 0 to 3,000 gallons/minute. In a preferred embodiment,the first fluidic material is pumped into the apparatus 2700 atoperating pressures and flow rates ranging from about 0 to 3,500 psi and0 to 1,200 gallons/minute in order to optimally provide operationalefficiency.

[0743] At a predetermined point in the injection of the first fluidicmaterial such as, for example, after the annular region outside of theapparatus 2700 has been filled to a predetermined level, a plug 2910,dart, or other similar device is introduced into the first fluidicmaterial. The plug 2910 lodges in the throat passage 2905 therebyfluidicly isolating the fluid passage 2810 from the fluid passage 2815.

[0744] After placement of the plug 2910 in the throat passage 2905, asecond fluidic material is pumped into the fluid passage 2795 in orderto pressurize the pressure chambers 2915 and 2920. The second fluidicmaterial may comprise any number of conventional commercially availablematerials such as, for example, water, drilling gases, drilling mud orlubricants. In a preferred embodiment, the second fluidic materialcomprises a non-hardenable fluidic material such as, for example, water,drilling mud or lubricant. The use of lubricant optimally provideslubrication of the moving parts of the apparatus 2700.

[0745] The second fluidic material may be pumped into the apparatus 2700at operating pressures and flow rates ranging, for example, from about 0to 4,500 psi and 0 to 4,500 gallons/minute. In a preferred embodiment,the second fluidic material is pumped into the apparatus 2700 atoperating pressures and flow rates ranging from about 0 to 3,500 psi and0 to 1,200 gallons/minute in order to optimally provide operationalefficiency.

[0746] The pressurization of the pressure chambers 2915 and 2920 causethe upper sealing heads, 2725 and 2745, outer sealing mandrels, 2735 and2755, and expansion cone 2765 to move in an axial direction. As theexpansion cone 2765 moves in the axial direction, the expansion cone2765 pulls the mandrel launcher 2770, casing 2790, and drag blocks 2785along, which sets the mechanical slips 2780 and stops further axialmovement of the mandrel launcher 2770 and casing 2790. In this manner,the axial movement of the expansion cone 2765 radially expands themandrel launcher 2770 and casing 2790.

[0747] Once the upper sealing heads, 2725 and 2745, outer sealingmandrels, 2735 and 2755, and expansion cone 2765 complete an axialstroke, the operating pressure of the second fluidic material is reducedand the drill string 2705 is raised. This causes the inner sealingmandrels, 2720 and 2740, lower sealing heads, 2730 and 2750, loadmandrel 2760, and mechanical slip body 2755 to move upward. This unsetsthe mechanical slips 2780 and permits the mechanical slips 2780 and dragblocks 2785 to be moved upward within the mandrel launcher 2770 andcasing 2790. When the lower sealing heads, 2730 and 2750, contact theupper sealing heads, 2725 and 2745, the second fluidic material is againpressurized and the radial expansion process continues. In this manner,the mandrel launcher 2770 and casing 2790 are radially expanded throughrepeated axial strokes of the upper sealing heads, 2725 and 2745, outersealing mandrels, 2735 and 2755, and expansion cone 2765. Throughout theradial expansion process, the upper end of the casing 2790 is preferablymaintained in an overlapping relation with an existing section ofwellbore casing.

[0748] At the end of the radial expansion process, the upper end of thecasing 2790 is expanded into intimate contact with the inside surface ofthe lower end of the existing wellbore casing. In a preferredembodiment, the sealing members provided at the upper end of the casing2790 provide a fluidic seal between the outside surface of the upper endof the casing 2790 and the inside surface of the lower end of theexisting wellbore casing. In a preferred embodiment, the contactpressure between the casing 2790 and the existing section of wellborecasing ranges from about 400 to 10,000 in order to optimally providecontact pressure for activating the sealing members, provide optimalresistance to axial movement of the expanded casing, and optimallyresist typical tensile and compressive loads on the expanded casing.

[0749] In a preferred embodiment, as the expansion cone 2765 nears theend of the casing 2790, the operating pressure of the second fluidicmaterial is reduced in order to minimize shock to the apparatus 2700. Inan alternative embodiment, the apparatus 2700 includes a shock absorberfor absorbing the shock created by the completion of the radialexpansion of the casing 2790.

[0750] In a preferred embodiment, the reduced operating pressure of thesecond fluidic material ranges from about 100 to 1,000 psi as theexpansion cone 2765 nears the end of the casing 2790 in order tooptimally provide reduced axial movement and velocity of the expansioncone 2765. In a preferred embodiment, the operating pressure of thesecond fluidic material is reduced during the return stroke of theapparatus 2700 to the range of about 0 to 500 psi in order minimize theresistance to the movement of the expansion cone 2765 during the returnstroke. In a preferred embodiment, the stroke length of the apparatus2700 ranges from about 10 to 45 feet in order to optimally provideequipment that can be easily handled by typical oil well riggingequipment and minimize the frequency at which the apparatus 2700 must bere-stroked during an expansion operation.

[0751] In an alternative embodiment, at least a portion of the uppersealing heads, 2725 and 2745, include expansion cones for radiallyexpanding the mandrel launcher 2770 and casing 2790 during operation ofthe apparatus 2700 in order to increase the surface area of the casing2790 acted upon during the radial expansion process. In this manner, theoperating pressures can be reduced.

[0752] In an alternative embodiment, mechanical slips are positioned inan axial location between the sealing sleeve 1915 and the first innersealing mandrel 2720 in order to optimally provide a simplified assemblyand operation of the apparatus 2700.

[0753] Upon the complete radial expansion of the casing 2790, ifapplicable, the first fluidic material is permitted to cure within theannular region between the outside of the expanded casing 2790 and theinterior walls of the wellbore. In the case where the casing 2790 isslotted, the cured fluidic material preferably permeates and envelopsthe expanded casing 2790. In this manner, a new section of wellborecasing is formed within a wellbore. Alternatively, the apparatus 2700may be used to join a first section of pipeline to an existing sectionof pipeline. Alternatively, the apparatus 2700 may be used to directlyline the interior of a wellbore with a casing, without the use of anouter annular layer of a hardenable material. Alternatively, theapparatus 2700 may be used to expand a tubular support member in a hole.

[0754] During the radial expansion process, the pressurized areas of theapparatus 2700 are limited to the fluid passages 2795, 2800, 2802, 2805,and 2810, and the pressure chambers 2915 and 2920. No fluid pressureacts directly on the mandrel launcher 2770 and casing 2790. This permitsthe use of operating pressures higher than the mandrel launcher 2770 andcasing 2790 could normally withstand.

[0755] Referring now to FIG. 20, a preferred embodiment of an apparatus3000 for forming a mono-diameter wellbore casing will be described. Theapparatus 3000 preferably includes a drillpipe 3005, an innerstringadapter 3010, a sealing sleeve 3015, a first inner sealing mandrel 3020,hydraulic slips 3025, a first upper sealing head 3030, a first lowersealing head 3035, a first outer sealing mandrel 3040, a second innersealing mandrel 3045, a second upper sealing head 3050, a second lowersealing head 3055, a second outer sealing mandrel 3060, load mandrel3065, expansion cone 3070, casing 3075, and fluid passages 3080, 3085,3090, 3095, 3100, 3105, 3110, 3115 and 3120.

[0756] The drillpipe 3005 is coupled to the innerstring adapter 3010.During operation of the apparatus 3000, the drillpipe 3005 supports theapparatus 3000. The drillpipe 3005 preferably comprises a substantiallyhollow tubular member or members. The drillpipe 3005 may be fabricatedfrom any number of conventional commercially available materials suchas, for example, oilfield country tubular goods, low alloy steel, carbonsteel, stainless steel or other similar high strength materials. In apreferred embodiment, the drillpipe 3005 is fabricated from coiledtubing in order to faciliate the placement of the apparatus 3000 innon-vertical wellbores. The drillpipe 3005 may be coupled to theinnerstring adapter 3010 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty threadedconnection, or a standard threaded connection. In a preferredembodiment, the drillpipe 3005 is removably coupled to the innerstringadapter 3010 by a drillpipe connection.

[0757] The drillpipe 3005 preferably includes a fluid passage 3080 thatis adapted to convey fluidic materials from a surface location into thefluid passage 3085. In a preferred embodiment, the fluid passage 3080 isadapted to convey fluidic materials such as, for example, cement, epoxy,water, drilling mud or lubricants at operating pressures and flow ratesranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute.

[0758] The innerstring adapter 3010 is coupled to the drill string 3005and the sealing sleeve 3015. The innerstring adapter 3010 preferablycomprises a substantially hollow tubular member or members. Theinnerstring adapter 3010 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel, or other similar high strength materials. In a preferredembodiment, the innerstring adapter 3010 is fabricated from stainlesssteel in order to optimally provide high strength, corrosion resistance,and low friction surfaces.

[0759] The innerstring adapter 3010 may be coupled to the drill string3005 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, or a standard threadedconnection. In a preferred embodiment, the innerstring adapter 3010 isremovably coupled to the drill pipe 3005 by a drillpipe connection. Theinnerstring adapter 3010 may be coupled to the sealing sleeve 3015 usingany number of conventional commercially available mechanical couplingssuch as, for example, drillpipe connection, oilfield country tubulargoods specialty type threaded connection, ratchet-latch type threadedconnection or a standard threaded connection. In a preferred embodiment,the innerstring adapter 3010 is removably coupled to the sealing sleeve3015 by a standard threaded connection.

[0760] The innerstring adapter 3010 preferably includes a fluid passage3085 that is adapted to convey fluidic materials from the fluid passage3080 into the fluid passage 3090. In a preferred embodiment, the fluidpassage 3085 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud, or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0761] The sealing sleeve 3015 is coupled to the innerstring adapter3010 and the first inner sealing mandrel 3020. The sealing sleeve 3015preferably comprises a substantially hollow tubular member or members.The sealing sleeve 3015 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the sealing sleeve 3015 is fabricated from stainless steelin order to optimally provide high strength, corrosion resistance, andlow friction surfaces.

[0762] The sealing sleeve 3015 may be coupled to the innerstring adapter3010 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, ratchet-latch typeconnection or a standard threaded connection. In a preferred embodiment,the sealing sleeve 3015 is removably coupled to the innerstring adapter3010 by a standard threaded connection. The sealing sleeve 3015 may becoupled to the first inner sealing mandrel 3020 using any number ofconventional commercially available mechanical couplings such as, forexample, drillpipe connection, oilfield country tubular goods specialtytype threaded connection, ratchet-latch type threaded connection or astandard threaded connection. In a preferred embodiment, the sealingsleeve 3015 is removably coupled to the first inner sealing mandrel 3020by a standard threaded connection.

[0763] The sealing sleeve 3015 preferably includes a fluid passage 3090that is adapted to convey fluidic materials from the fluid passage 3085into the fluid passage 3095. In a preferred embodiment, the fluidpassage 3090 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud, or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0764] The first inner sealing mandrel 3020 is coupled to the sealingsleeve 3015, the hydraulic slips 3025, and the first lower sealing head3035. The first inner sealing mandrel 3020 is further movably coupled tothe first upper sealing head 3030. The first inner sealing mandrel 3020preferably comprises a substantially hollow tubular member or members.The first inner sealing mandrel 3020 may be fabricated from any numberof conventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel, or similar high strength materials. In a preferred embodiment,the first inner sealing mandrel 3020 is fabricated from stainless steelin order to optimally provide high strength, corrosion resistance, andlow friction surfaces.

[0765] The first inner sealing mandrel 3020 may be coupled to thesealing sleeve 3015 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection or a standardthreaded connection. In a preferred embodiment, the first inner sealingmandrel 3020 is removably coupled to the sealing sleeve 3015 by astandard threaded connection. The first inner sealing mandrel 3020 maybe coupled to the hydraulic slips 3025 using any number of conventionalcommercially available mechanical couplings such as, for example,drillpipe connection, oilfield country tubular goods specialty typethreaded connection, ratchet-latch type threaded connection or astandard threaded connection. In a preferred embodiment, the first innersealing mandrel 3020 is removably coupled to the hydraulic slips 3025 bya standard threaded connection. The first inner sealing mandrel 3020 maybe coupled to the first lower sealing head 3035 using any number ofconventional commercially available mechanical couplings such as, forexample, drillpipe connection, oilfield country tubular goods specialtytype threaded connection, ratchet-latch type threaded connection or astandard threaded connection. In a preferred embodiment, the first innersealing mandrel 3020 is removably coupled to the first lower sealinghead 3035 by a standard threaded connection.

[0766] The first inner sealing mandrel 3020 preferably includes a fluidpassage 3095 that is adapted to convey fluidic materials from the fluidpassage 3090 into the fluid passage 3100. In a preferred embodiment, thefluid passage 3095 is adapted to convey fluidic materials such as, forexample, water, drilling mud, cement, epoxy, or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0767] The first inner sealing mandrel 3020 further preferably includesfluid passages 3110 that are adapted to convey fluidic materials fromthe fluid passage 3095 into the pressure chambers of the hydraulic slips3025. In this manner, the slips 3025 are activated upon thepressurization of the fluid passage 3095 into contact with the insidesurface of the casing 3075. In a preferred embodiment, the fluidpassages 3110 are adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling fluids or lubricants atoperating pressures and flow rates ranging from about 0 to 9,000 psi and0 to 3,000 gallons/minute.

[0768] The first inner sealing mandrel 3020 further preferably includesfluid passages 3115 that are adapted to convey fluidic materials fromthe fluid passage 3095 into the first pressure chamber 3175 defined bythe first upper sealing head 3030, the first lower sealing head 3035,the first inner sealing mandrel 3020, and the first outer sealingmandrel 3040. During operation of the apparatus 3000, pressurization ofthe pressure chamber 3175 causes the first upper sealing head 3030, thefirst outer sealing mandrel 3040, the second upper sealing head 3050,the second outer sealing mandrel 3060, and the expansion cone 3070 tomove in an axial direction.

[0769] The slips 3025 are coupled to the outside surface of the firstinner sealing mandrel 3020. During operation of the apparatus 3000, theslips 3025 are activated upon the pressurization of the fluid passage3095 into contact with the inside surface of the casing 3075. In thismanner, the slips 3025 maintain the casing 3075 in a substantiallystationary position.

[0770] The slips 3025 preferably include fluid passages 3125, pressurechambers 3130, spring bias 3135, and slip members 3140. The slips 3025may comprise any number of conventional commercially available hydraulicslips such as, for example, RTTS packer tungsten carbide hydraulic slipsor Model 3L retrievable bridge plug with hydraulic slips. In a preferredembodiment, the slips 3025 comprise RTTS packer tungsten carbidehydraulic slips available from Halliburton Energy Services in order tooptimally provide resistance to axial movement of the casing 3075 duringthe expansion process.

[0771] The first upper sealing head 3030 is coupled to the first outersealing mandrel 3040, the second upper sealing head 3050, the secondouter sealing mandrel 3060, and the expansion cone 3070. The first uppersealing head 3030 is also movably coupled to the outer surface of thefirst inner sealing mandrel 3020 and the inner surface of the casing3075. In this manner, the first upper sealing head 3030, the first outersealing mandrel 3040, the second upper sealing head 3050, the secondouter sealing mandrel 3060, and the expansion cone 3070 reciprocate inthe axial direction.

[0772] The radial clearance between the inner cylindrical surface of thefirst upper sealing head 3030 and the outer surface of the first innersealing mandrel 3020 may range, for example, from about 0.0025 to 0.05inches. In a preferred embodiment, the radial clearance between theinner cylindrical surface of the first upper sealing head 3030 and theouter surface of the first inner sealing mandrel 3020 ranges from about0.005 to 0.01 inches in order to optimally provide minimal radialclearance. The radial clearance between the outer cylindrical surface ofthe first upper sealing head 3030 and the inner surface of the casing3075 may range, for example, from about 0.025 to 0.375 inches. In apreferred embodiment, the radial clearance between the outer cylindricalsurface of the first upper sealing head 3030 and the inner surface ofthe casing 3075 ranges from about 0.025 to 0.125 inches in order tooptimally provide stabilization for the expansion cone 3070 during theexpansion process.

[0773] The first upper sealing head 3030 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Thefirst upper sealing head 3030 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, or othersimilar high strength materials. In a preferred embodiment, the firstupper sealing head 3030 is fabricated from stainless steel in order tooptimally provide high strength, corrosion resistance, and low frictionsurfaces. The inner surface of the first upper sealing head 3030preferably includes one or more annular sealing members 3145 for sealingthe interface between the first upper sealing head 3030 and the firstinner sealing mandrel 3020. The sealing members 3145 may comprise anynumber of conventional commercially available annular sealing memberssuch as, for example, o-rings, polypak seals or metal spring energizedseals. In a preferred embodiment, the sealing members 3145 comprisepolypak seals available from Parker seals in order to optimally providesealing for a long axial stroke.

[0774] In a preferred embodiment, the first upper sealing head 3030includes a shoulder 3150 for supporting the first upper sealing head3030, first outer sealing mandrel 3040, second upper sealing head 3050,second outer sealing mandrel 3060, and expansion cone 3070 on the firstlower sealing head 3035. The first upper sealing head 3030 may becoupled to the first outer sealing mandrel 3040 using any number ofconventional commercially available mechanical couplings such as, forexample, drillpipe connection, oilfield country tubular goods specialtytype threaded connection, or a standard threaded connection. In apreferred embodiment, the first upper sealing head 3030 is removablycoupled to the first outer sealing mandrel 3040 by a standard threadedconnection. In a preferred embodiment, the mechanical coupling betweenthe first upper sealing head 3030 and the first outer sealing mandrel3040 includes one or more sealing members 3155 for fluidicly sealing theinterface between the first upper sealing head 3030 and the first outersealing mandrel 3040. The sealing members 3155 may comprise any numberof conventional commercially available sealing members such as, forexample, o-rings, polypak seals, or metal spring energized seals. In apreferred embodiment, the sealing members 3155 comprise polypak sealsavailable from Parker Seals in order to optimally provide sealing for along axial stroke.

[0775] The first lower sealing head 3035 is coupled to the first innersealing mandrel 3020 and the second inner sealing mandrel 3045. Thefirst lower sealing head 3035 is also movably coupled to the innersurface of the first outer sealing mandrel 3040. In this manner, thefirst upper sealing head 3030, first outer sealing mandrel 3040, secondupper sealing head 3050, second outer sealing mandrel 3060, andexpansion cone 3070 reciprocate in the axial direction. The radialclearance between the outer surface of the first lower sealing head 3035and the inner surface of the first outer sealing mandrel 3040 may range,for example, from about 0.0025 to 0.05 inches. In a preferredembodiment, the radial clearance between the outer surface of the firstlower sealing head 3035 and the inner surface of the outer sealingmandrel 3040 ranges from about 0.005 to 0.01 inches in order tooptimally provide minimal radial clearance.

[0776] The first lower sealing head 3035 preferably comprises an annularmember having substantially cylindrical inner and outer surfaces. Thefirst lower sealing head 3035 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel, stainlesssteel or other similar high strength materials. In a preferredembodiment, the first lower sealing head 3035 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance, and low friction surfaces. The outer surface of the firstlower sealing head 3035 preferably includes one or more annular sealingmembers 3160 for sealing the interface between the first lower sealinghead 3035 and the first outer sealing mandrel 3040. The sealing members3160 may comprise any number of conventional commercially availableannular sealing members such as, for example, o-rings, polypak seals, ormetal spring energized seals. In a preferred embodiment, the sealingmembers 3160 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for a long axial stroke.

[0777] The first lower sealing head 3035 may be coupled to the firstinner sealing mandrel 3020 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection or a standardthreaded connection. In a preferred embodiment, the first lower sealinghead 3035 is removably coupled to the first inner sealing mandrel 3020by a standard threaded connection. In a preferred embodiment, themechanical coupling between the first lower sealing head 3035 and thefirst inner sealing mandrel 3020 includes one or more sealing members3165 for fluidicly sealing the interface between the first lower sealinghead 3035 and the first inner sealing mandrel 3020. The sealing members3165 may comprise any number of conventional commercially availablesealing members such as, for example, o-rings, polypak seals, or metalspring energized seals. In a preferred embodiment, the sealing members3165 comprise polypak seals available from Parker Seals in order tooptimally provide sealing for a long axial stroke length.

[0778] The first lower sealing head 3035 may be coupled to the secondinner sealing mandrel 3045 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection or a standardthreaded connection. In a preferred embodiment, the first lower sealinghead 3035 is removably coupled to the second inner sealing mandrel 3045by a standard threaded connection. In a preferred embodiment, themechanical coupling between the first lower sealing head 3035 and thesecond inner sealing mandrel 3045 includes one or more sealing members3170 for fluidicly sealing the interface between the first lower sealinghead 3035 and the second inner sealing mandrel 3045. The sealing members3170 may comprise any number of conventional commercially availablesealing members such as, for example, o-rings, polypak seals or metalspring energized seals. In a preferred embodiment, the sealing members3170 comprise polypak seals available from Parker Seals in order tooptimally provide sealing for a long axial stroke.

[0779] The first outer sealing mandrel 3040 is coupled to the firstupper sealing head 3030 and the second upper sealing head 3050. Thefirst outer sealing mandrel 3040 is also movably coupled to the innersurface of the casing 3075 and the outer surface of the first lowersealing head 3035. In this manner, the first upper sealing head 3030,first outer sealing mandrel 3040, second upper sealing head 3050, secondouter sealing mandrel 3060, and the expansion cone 3070 reciprocate inthe axial direction. The radial clearance between the outer surface ofthe first outer sealing mandrel 3040 and the inner surface of the casing3075 may range, for example, from about 0.025 to 0.375 inches. In apreferred embodiment, the radial clearance between the outer surface ofthe first outer sealing mandrel 3040 and the inner surface of the casing3075 ranges from about 0.025 to 0.125 inches in order to optimallyprovide stabilization for the expansion cone 3070 during the expansionprocess. The radial clearance between the inner surface of the firstouter sealing mandrel 3040 and the outer surface of the first lowersealing head 3035 may range, for example, from about 0.005 to 0.125inches. In a preferred embodiment, the radial clearance between theinner surface of the first outer sealing mandrel 3040 and the outersurface of the first lower sealing head 3035 ranges from about 0.005 to0.01 inches in order to optimally provide minimal radial clearance.

[0780] The first outer sealing mandrel 3040 preferably comprises anannular member having substantially cylindrical inner and outersurfaces. The first outer sealing mandrel 3040 may be fabricated fromany number of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel or other similar high strength materials. In a preferredembodiment, the first outer sealing mandrel 3040 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance, and low friction surfaces.

[0781] The first outer sealing mandrel 3040 may be coupled to the firstupper sealing head 3030 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection or a standardthreaded connection. In a preferred embodiment, the first outer sealingmandrel 3040 is removably coupled to the first upper sealing head 3030by a standard threaded connection. In a preferred embodiment, themechanical coupling between the first outer sealing mandrel 3040 and thefirst upper sealing head 3030 includes one or more sealing members 3180for sealing the interface between the first outer sealing mandrel 3040and the first upper sealing head 3030. The sealing members 3180 maycomprise any number of conventional commercially available sealingmembers such as, for example, o-rings, polypak seals or metal springenergized seals. In a preferred embodiment, the sealing members 3180comprise polypak seals available from Parker Seals in order to optimallyprovide sealing for a long axial stroke.

[0782] The first outer sealing mandrel 3040 may be coupled to the secondupper sealing head 3050 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection, or a standardthreaded connection. In a preferred embodiment, the first outer sealingmandrel 3040 is removably coupled to the second upper sealing head 3050by a standard threaded connection. In a preferred embodiment, themechanical coupling between the first outer sealing mandrel 3040 and thesecond upper sealing head 3050 includes one or more sealing members 3185for sealing the interface between the first outer sealing mandrel 3040and the second upper sealing head 3050. The sealing members 3185 maycomprise any number of conventional commercially available sealingmembers such as, for example, o-rings, polypak seals or metal springenergized seals. In a preferred embodiment, the sealing members 3185comprise polypak seals available from Parker Seals in order to optimallyprovide sealing for a long axial stroke.

[0783] The second inner sealing mandrel 3045 is coupled to the firstlower sealing head 3035 and the second lower sealing head 3055. Thesecond inner sealing mandrel 3045 preferably comprises a substantiallyhollow tubular member or members. The second inner sealing mandrel 3045may be fabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, stainless steel or other similar highstrength materials. In a preferred embodiment, the second inner sealingmandrel 3045 is fabricated from stainless steel in order to optimallyprovide high strength, corrosion resistance, and low friction surfaces.

[0784] The second inner sealing mandrel 3045 may be coupled to the firstlower sealing head 3035 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection or a standardthreaded connection. In a preferred embodiment, the second inner sealingmandrel 3045 is removably coupled to the first lower sealing head 3035by a standard threaded connection. The second inner sealing mandrel 3045may be coupled to the second lower sealing head 3055 using any number ofconventional commercially available mechanical couplings such as, forexample, drillpipe connection, oilfield country tubular goods specialtytype threaded connection, ratchet-latch type connection, or a standardthreaded connection. In a preferred embodiment, the second inner sealingmandrel 3045 is removably coupled to the second lower sealing head 3055by a standard threaded connection.

[0785] The second inner sealing mandrel 3045 preferably includes a fluidpassage 3100 that is adapted to convey fluidic materials from the fluidpassage 3095 into the fluid passage 3105. In a preferred embodiment, thefluid passage 3100 is adapted to convey fluidic materials such as, forexample, cement, epoxy, water, drilling mud or lubricants at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute.

[0786] The second inner sealing mandrel 3045 further preferably includesfluid passages 3120 that are adapted to convey fluidic materials fromthe fluid passage 3100 into the second pressure chamber 3190 defined bythe second upper sealing head 3050, the second lower sealing head 3055,the second inner sealing mandrel 3045, and the second outer sealingmandrel 3060. During operation of the apparatus 3000, pressurization ofthe second pressure chamber 3190 causes the first upper sealing head3030, the first outer sealing mandrel 3040, the second upper sealinghead 3050, the second outer sealing mandrel 3060, and the expansion cone3070 to move in an axial direction.

[0787] The second upper sealing head 3050 is coupled to the first outersealing mandrel 3040 and the second outer sealing mandrel 3060. Thesecond upper sealing head 3050 is also movably coupled to the outersurface of the second inner sealing mandrel 3045 and the inner surfaceof the casing 3075. In this manner, the second upper sealing head 3050reciprocates in the axial direction. The radial clearance between theinner cylindrical surface of the second upper sealing head 3050 and theouter surface of the second inner sealing mandrel 3045 may range, forexample, from about 0.0025 to 0.05 inches. In a preferred embodiment,the radial clearance between the inner cylindrical surface of the secondupper sealing head 3050 and the outer surface of the second innersealing mandrel 3045 ranges from about 0.005 to 0.01 inches in order tooptimally provide minimal radial clearance. The radial clearance betweenthe outer cylindrical surface of the second upper sealing head 3050 andthe inner surface of the casing 3075 may range, for example, from about0.025 to 0.375 inches. In a preferred embodiment, the radial clearancebetween the outer cylindrical surface of the second upper sealing head3050 and the inner surface of the casing 3075 ranges from about 0.025 to0.125 inches in order to optimally provide stabilization for theexpansion cone 3070 during the expansion process.

[0788] The second upper sealing head 3050 preferably comprises anannular member having substantially cylindrical inner and outersurfaces. The second upper sealing head 3050 may be fabricated from anynumber of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel or other similar high strength materials. In a preferredembodiment, the second upper sealing head 3050 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance, and low friction surfaces. The inner surface of the secondupper sealing head 3050 preferably includes one or more annular sealingmembers 3195 for sealing the interface between the second upper sealinghead 3050 and the second inner sealing mandrel 3045. The sealing members3195 may comprise any number of conventional commercially availableannular sealing members such as, for example, o-rings, polypak seals ormetal spring energized seals. In a preferred embodiment, the sealingmembers 3195 comprise polypak seals available from Parker Seals in orderto optimally provide sealing for a long axial stroke.

[0789] In a preferred embodiment, the second upper sealing head 3050includes a shoulder 3200 for supporting the first upper sealing head3030, first outer sealing mandrel 3040, second upper sealing head 3050,second outer sealing mandrel 3060, and expansion cone 3070 on the secondlower sealing head 3055.

[0790] The second upper sealing head 3050 may be coupled to the firstouter sealing mandrel 3040 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type threaded connection, or a standardthreaded connection. In a preferred embodiment, the second upper sealinghead 3050 is removably coupled to the first outer sealing mandrel 3040by a standard threaded connection. In a preferred embodiment, themechanical coupling between the second upper sealing head 3050 and thefirst outer sealing mandrel 3040 includes one or more sealing members3185 for fluidicly sealing the interface between the second uppersealing head 3050 and the first outer sealing mandrel 3040. The secondupper sealing head 3050 may be coupled to the second outer sealingmandrel 3060 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection,ratchet-latch type threaded connection, or a standard threadedconnection. In a preferred embodiment, the second upper sealing head3050 is removably coupled to the second outer sealing mandrel 3060 by astandard threaded connection. In a preferred embodiment, the mechanicalcoupling between the second upper sealing head 3050 and the second outersealing mandrel 3060 includes one or more sealing members 3205 forfluidicly sealing the interface between the second upper sealing head3050 and the second outer sealing mandrel 3060.

[0791] The second lower sealing head 3055 is coupled to the second innersealing mandrel 3045 and the load mandrel 3065. The second lower sealinghead 3055 is also movably coupled to the inner surface of the secondouter sealing mandrel 3060. In this manner, the first upper sealing head3030, first outer sealing mandrel 3040, second upper sealing mandrel3050, second outer sealing mandrel 3060, and expansion cone 3070reciprocate in the axial direction. The radial clearance between theouter surface of the second lower sealing head 3055 and the innersurface of the second outer sealing mandrel 3060 may range, for example,from about 0.0025 to 0.05 inches. In a preferred embodiment, the radialclearance between the outer surface of the second lower sealing head3055 and the inner surface of the second outer sealing mandrel 3060ranges from about 0.005 to 0.01 inches in order to optimally provideminimal radial clearance.

[0792] The second lower sealing head 3055 preferably comprises anannular member having substantially cylindrical inner and outersurfaces. The second lower sealing head 3055 may be fabricated from anynumber of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel, or other similar high strength materials. In apreferred embodiment, the second lower sealing head 3055 is fabricatedfrom stainless steel in order to optimally provide high strength,corrosion resistance, and low friction surfaces. The outer surface ofthe second lower sealing head 3055 preferably includes one or moreannular sealing members 3210 for sealing the interface between thesecond lower sealing head 3055 and the second outer sealing mandrel3060. The sealing members 3210 may comprise any number of conventionalcommercially available annular sealing members such as, for example,o-rings, polypak seals, or metal spring energized seals. In a preferredembodiment, the sealing members 3210 comprise polypak seals availablefrom Parker Seals in order to optimally provide sealing for long axialstrokes.

[0793] The second lower sealing head 3055 may be coupled to the secondinner sealing mandrel 3045 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, or a standard threaded connection. In a preferredembodiment, the second lower sealing head 3055 is removably coupled tothe second inner sealing mandrel 3045 by a standard threaded connection.In a preferred embodiment, the mechanical coupling between the lowersealing head 3055 and the second inner sealing mandrel 3045 includes oneor more sealing members 3215 for fluidicly sealing the interface betweenthe second lower sealing head 3055 and the second inner sealing mandrel3045. The sealing members 3215 may comprise any number of conventionalcommercially available sealing members such as, for example, o-rings,polypak seals or metal spring energized seals. In a preferredembodiment, the sealing members 3215 comprise polypak seals availablefrom Parker Seals in order to optimally provide sealing for long axialstrokes.

[0794] The second lower sealing head 3055 may be coupled to the loadmandrel 3065 using any number of conventional commercially availablemechanical couplings such as, for example, drillpipe connection,oilfield country tubular goods specialty type threaded connection, or astandard threaded connection. In a preferred embodiment, the secondlower sealing head 3055 is removably coupled to the load mandrel 3065 bya standard threaded connection. In a preferred embodiment, themechanical coupling between the second lower sealing head 3055 and theload mandrel 3065 includes one or more sealing members 3220 forfluidicly sealing the interface between the second lower sealing head3055 and the load mandrel 3065. The sealing members 3220 may compriseany number of conventional commercially available sealing members suchas, for example, o-rings, polypak seals or metal spring energized seals.In a preferred embodiment, the sealing members 3220 comprise polypakseals available from Parker Seals in order to optimally provide sealingfor a long axial stroke.

[0795] In a preferred embodiment, the second lower sealing head 3055includes a throat passage 3225 fluidicly coupled between the fluidpassages 3100 and 3105. The throat passage 3225 is preferably of reducedsize and is adapted to receive and engage with a plug 3230, or othersimilar device. In this manner, the fluid passage 3100 is fluidiclyisolated from the fluid passage 3105. In this manner, the pressurechambers 3175 and 3190 are pressurized. Furthermore, the placement ofthe plug 3230 in the throat passage 3225 also pressurizes the pressurechambers 3130 of the hydraulic slips 3025.

[0796] The second outer sealing mandrel 3060 is coupled to the secondupper sealing head 3050 and the expansion cone 3070. The second outersealing mandrel 3060 is also movably coupled to the inner surface of thecasing 3075 and the outer surface of the second lower sealing head 3055.In this manner, the first upper sealing head 3030, first outer sealingmandrel 3040, second upper sealing head 3050, second outer sealingmandrel 3060, and the expansion cone 3070 reciprocate in the axialdirection. The radial clearance between the outer surface of the secondouter sealing mandrel 3060 and the inner surface of the casing 3075 mayrange, for example, from about 0.025 to 0.375 inches. In a preferredembodiment, the radial clearance between the outer surface of the secondouter sealing mandrel 3060 and the inner surface of the casing 3075ranges from about 0.025 to 0.125 inches in order to optimally providestabilization for the expansion cone 3070 during the expansion process.The radial clearance between the inner surface of the second outersealing mandrel 3060 and the outer surface of the second lower sealinghead 3055 may range, for example, from about 0.0025 to 0.05 inches. In apreferred embodiment, the radial clearance between the inner surface ofthe second outer sealing mandrel 3060 and the outer surface of thesecond lower sealing head 3055 ranges from about 0.005 to 0.01 inches inorder to optimally provide minimal radial clearance.

[0797] The second outer sealing mandrel 3060 preferably comprises anannular member having substantially cylindrical inner and outersurfaces. The second outer sealing mandrel 3060 may be fabricated fromany number of conventional commercially available materials such as, forexample, oilfield country tubular goods, low alloy steel, carbon steel,stainless steel or other similar high strength materials. In a preferredembodiment, the second outer sealing mandrel 3060 is fabricated fromstainless steel in order to optimally provide high strength, corrosionresistance, and low friction surfaces.

[0798] The second outer sealing mandrel 3060 may be coupled to thesecond upper sealing head 3050 using any number of conventionalcommercially available mechanical couplings such as, for example,drillpipe connection, oilfield country tubular goods specialty typethreaded connection, or a standard threaded connection. In a preferredembodiment, the outer sealing mandrel 3060 is removably coupled to thesecond upper sealing head 3050 by a standard threaded connection. Thesecond outer sealing mandrel 3060 may be coupled to the expansion cone3070 using any number of conventional commercially available mechanicalcouplings such as, for example, drillpipe connection, oilfield countrytubular goods specialty type threaded connection, or a standard threadedconnection. In a preferred embodiment, the second outer sealing mandrel3060 is removably coupled to the expansion cone 3070 by a standardthreaded connection.

[0799] The first upper sealing head 3030, the first lower sealing head3035, the first inner sealing mandrel 3020, and the first outer sealingmandrel 3040 together define the first pressure chamber 3175. The secondupper sealing head 3050, the second lower sealing head 3055, the secondinner sealing mandrel 3045, and the second outer sealing mandrel 3060together define the second pressure chamber 3190. The first and secondpressure chambers, 3175 and 3190, are fluidicly coupled to the passages,3095 and 3100, via one or more passages, 3115 and 3120. During operationof the apparatus 3000, the plug 3230 engages with the throat passage3225 to fluidicly isolate the fluid passage 3100 from the fluid passage3105. The pressure chambers, 3175 and 3190, are then pressurized whichin turn causes the first upper sealing head 3030, the first outersealing mandrel 3040, the second upper sealing head 3050, the secondouter sealing mandrel 3060, and expansion cone 3070 to reciprocate inthe axial direction. The axial motion of the expansion cone 3070 in turnexpands the casing 3075 in the radial direction. The use of a pluralityof pressure chambers, 3175 and 3190, effectively multiplies theavailable driving force for the expansion cone 3070.

[0800] The load mandrel 3065 is coupled to the second lower sealing head3055. The load mandrel 3065 preferably comprises an annular memberhaving substantially cylindrical inner and outer surfaces. The loadmandrel 3065 may be fabricated from any number of conventionalcommercially available materials such as, for example, oilfield countrytubular goods, low alloy steel, carbon steel, stainless steel or othersimilar high strength materials. In a preferred embodiment, the loadmandrel 3065 is fabricated from stainless steel in order to optimallyprovide high strength, corrosion resistance, and low friction surfaces.

[0801] The load mandrel 3065 may be coupled to the lower sealing head3055 using any number of conventional commercially available mechanicalcouplings such as, for example, epoxy, cement, water, drilling mud, orlubricants. In a preferred embodiment, the load mandrel 3065 isremovably coupled to the lower sealing head 3055 by a standard threadedconnection.

[0802] The load mandrel 3065 preferably includes a fluid passage 3105that is adapted to convey fluidic materials from the fluid passage 3100to the region outside of the apparatus 3000. In a preferred embodiment,the fluid passage 3105 is adapted to convey fluidic materials such as,for example, cement, epoxy, water, drilling mud or lubricants atoperating pressures and flow rates ranging from about 0 to 9,000 psi and0 to 3,000 gallons/minute.

[0803] The expansion cone 3070 is coupled to the second outer sealingmandrel 3060. The expansion cone 3070 is also movably coupled to theinner surface of the casing 3075. In this manner, the first uppersealing head 3030, first outer sealing mandrel 3040, second uppersealing head 3050, second outer sealing mandrel 3060, and the expansioncone 3070 reciprocate in the axial direction. The reciprocation of theexpansion cone 3070 causes the casing 3075 to expand in the radialdirection.

[0804] The expansion cone 3070 preferably comprises an annular memberhaving substantially cylindrical inner and conical outer surfaces. Theoutside radius of the outside conical surface may range, for example,from about 2 to 34 inches. In a preferred embodiment, the outside radiusof the outside conical surface ranges from about 3 to 28 inches in orderto optimally provide an expansion cone 3070 for expanding typicalcasings. The axial length of the expansion cone 3070 may range, forexample, from about 2 to 8 times the maximum outer diameter of theexpansion cone 3070. In a preferred embodiment, the axial length of theexpansion cone 3070 ranges from about 3 to 5 times the maximum outerdiameter of the expansion cone 3070 in order to optimally providestabilization and centralization of the expansion cone 3070 during theexpansion process. In a particularly preferred embodiment, the maximumoutside diameter of the expansion cone 3070 is between about 95 to 99%of the inside diameter of the existing wellbore that the casing 3075will be joined with. In a preferred embodiment, the angle of attack ofthe expansion cone 3070 ranges from about 5 to 30 degrees in order tooptimally balance the frictional forces with the radial expansionforces.

[0805] The expansion cone 3070 may be fabricated from any number ofconventional commercially available materials such as, for example,machine tool steel, nitride steel, titanium, tungsten carbide, ceramics,or other similar high strength materials. In a preferred embodiment, theexpansion cone 3070 is fabricated from D2 machine tool steel in order tooptimally provide high strength and resistance to wear and galling. In aparticularly preferred embodiment, the outside surface of the expansioncone 3070 has a surface hardness ranging from about 58 to 62 Rockwell Cin order to optimally provide high strength and resistance to wear andgalling.

[0806] The expansion cone 3070 may be coupled to the second outsidesealing mandrel 3060 using any number of conventional commerciallyavailable mechanical couplings such as, for example, drillpipeconnection, oilfield country tubular goods specialty type threadedconnection, ratchet-latch type connection or a standard threadedconnection. In a preferred embodiment, the expansion cone 3070 iscoupled to the second outside sealing mandrel 3060 using a standardthreaded connection in order to optimally provide high strength and easydisassembly.

[0807] The casing 3075 is removably coupled to the slips 3025 and theexpansion cone 3070. The casing 3075 preferably comprises a tubularmember. The casing 3075 may be fabricated from any number ofconventional commercially available materials such as, for example,slotted tubulars, oilfield country tubular goods, carbon steel, lowalloy steel, stainless steel, or other similar high strength materials.In a preferred embodiment, the casing 3075 is fabricated from oilfieldcountry tubular goods available from various foreign and domestic steelmills in order to optimally provide high strength.

[0808] In a preferred embodiment, the upper end 3235 of the casing 3075includes a thin wall section 3240 and an outer annular sealing member3245. In a preferred embodiment, the wall thickness of the thin wallsection 3240 is about 50 to 100% of the regular wall thickness of thecasing 3075. In this manner, the upper end 3235 of the casing 3075 maybe easily radially expanded and deformed into intimate contact with thelower end of an existing section of wellbore casing. In a preferredembodiment, the lower end of the existing section of casing alsoincludes a thin wall section. In this manner, the radial expansion ofthe thin walled section 3240 of casing 3075 into the thin walled sectionof the existing wellbore casing results in a wellbore casing having asubstantially constant inside diameter.

[0809] The annular sealing member 3245 may be fabricated from any numberof conventional commercially available sealing materials such as, forexample, epoxy, rubber, metal or plastic. In a preferred embodiment, theannular sealing member 3245 is fabricated from StrataLock epoxy in orderto optimally provide compressibility and wear resistance. The outsidediameter of the annular sealing member 3245 preferably ranges from about70 to 95% of the inside diameter of the lower section of the wellborecasing that the casing 3075 is joined to. In this manner, after radialexpansion, the annular sealing member 3245 optimally provides a fluidicseal and also preferably optimally provides sufficient frictional forcewith the inside surface of the existing section of wellbore casingduring the radial expansion of the casing 3075 to support the casing3075.

[0810] In a preferred embodiment, the lower end 3250 of the casing 3075includes a thin wall section 3255 and an outer annular sealing member3260. In a preferred embodiment, the wall thickness of the thin wallsection 3255 is about 50 to 100% of the regular wall thickness of thecasing 3075. In this manner, the lower end 3250 of the casing 3075 maybe easily expanded and deformed. Furthermore, in this manner, an othersection of casing may be easily joined with the lower end 3250 of thecasing 3075 using a radial expansion process. In a preferred embodiment,the upper end of the other section of casing also includes a thin wallsection. In this manner, the radial expansion of the thin walled sectionof the upper end of the other casing into the thin walled section 3255of the lower end 3250 of the casing 3075 results in a wellbore casinghaving a substantially constant inside diameter.

[0811] The upper annular sealing member 3245 may be fabricated from anynumber of conventional commercially available sealing materials such as,for example, epoxy, rubber, metal or plastic. In a preferred embodiment,the upper annular sealing member 3245 is fabricated from Stratalockepoxy in order to optimally provide compressibility and resistance towear. The outside diameter of the upper annular sealing member 3245preferably ranges from about 70 to 95% of the inside diameter of thelower section of the existing wellbore casing that the casing 3075 isjoined to. In this manner, after radial expansion, the upper annularsealing member 3245 preferably provides a fluidic seal and alsopreferably provides sufficient frictional force with the inside wall ofthe wellbore during the radial expansion of the casing 3075 to supportthe casing 3075.

[0812] The lower annular sealing member 3260 may be fabricated from anynumber of conventional commercially available sealing materials such as,for example, epoxy, rubber, metal or plastic. In a preferred embodiment,the lower annular sealing member 3260 is fabricated from StrataLockepoxy in order to optimally provide compressibility and resistance towear. The outside diameter of the lower annular sealing member 3260preferably ranges from about 70 to 95% of the inside diameter of thelower section of the existing wellbore casing that the casing 3075 isjoined to. In this manner, the lower annular sealing member 3260preferably provides a fluidic seal and also preferably providessufficient frictional force with the inside wall of the wellbore duringthe radial expansion of the casing 3075 to support the casing 3075.

[0813] During operation, the apparatus 3000 is preferably positioned ina wellbore with the upper end 3235 of the casing 3075 positioned in anoverlapping relationship with the lower end of an existing wellborecasing. In a particularly preferred embodiment, the thin wall section3240 of the casing 3075 is positioned in opposing overlapping relationwith the thin wall section and outer annular sealing member of the lowerend of the existing section of wellbore casing. In this manner, theradial expansion of the casing 3075 will compress the thin wall sectionsand annular compressible members of the upper end 3235 of the casing3075 and the lower end of the existing wellbore casing into intimatecontact. During the positioning of the apparatus 3000 in the wellbore,the casing 3000 is preferably supported by the expansion cone 3070.

[0814] After positioning the apparatus 3000, a first fluidic material isthen pumped into the fluid passage 3080. The first fluidic material maycomprise any number of conventional commercially available materialssuch as, for example, drilling mud, water, epoxy, cement, slag mix orlubricants. In a preferred embodiment, the first fluidic materialcomprises a hardenable fluidic sealing material such as, for example,cement, epoxy, or slag mix in order to optimally provide a hardenableouter annular body around the expanded casing 3075.

[0815] The first fluidic material may be pumped into the fluid passage3080 at operating pressures and flow rates ranging, for example, fromabout 0 to 4,500 psi and 0 to 4,500 gallons/minute. In a preferredembodiment, the first fluidic material is pumped into the fluid passage3080 at operating pressures and flow rates ranging from about 0 to 3,500psi and 0 to 1,200 gallons/minute in order to optimally provideoperating efficiency.

[0816] The first fluidic material pumped into the fluid passage 3080passes through the fluid passages 3085, 3090, 3095, 3100, and 3105 andthen outside of the apparatus 3000. The first fluidic material thenpreferably fills the annular region between the outside of the apparatus3000 and the interior walls of the wellbore.

[0817] The plug 3230 is then introduced into the fluid passage 3080. Theplug 3230 lodges in the throat passage 3225 and fluidicly isolates andblocks off the fluid passage 3100. In a preferred embodiment, a coupleof volumes of a non-hardenable fluidic material are then pumped into thefluid passage 3080 in order to remove any hardenable fluidic materialcontained within and to ensure that none of the fluid passages areblocked.

[0818] A second fluidic material is then pumped into the fluid passage3080. The second fluidic material may comprise any number ofconventional commercially available materials such as, for example,water, drilling gases, drilling mud or lubricant. In a preferredembodiment, the second fluidic material comprises a non-hardenablefluidic material such as, for example, water, drilling mud, drillinggases, or lubricant in order to optimally provide pressurization of thepressure chambers 3175 and 3190.

[0819] The second fluidic material may be pumped into the fluid passage3080 at operating pressures and flow rates ranging, for example, fromabout 0 to 4,500 psi and 0 to 4,500 gallons/minute. In a preferredembodiment, the second fluidic material is pumped into the fluid passage3080 at operating pressures and flow rates ranging from about 0 to 3,500psi and 0 to 1,200 gallons/minute in order to optimally provideoperational efficiency.

[0820] The second fluidic material pumped into the fluid passage 3080passes through the fluid passages 3085, 3090, 3095, 3100 and into thepressure chambers 3130 of the slips 3025, and into the pressure chambers3175 and 3190. Continued pumping of the second fluidic materialpressurizes the pressure chambers 3130, 3175, and 3190.

[0821] The pressurization of the pressure chambers 3130 causes thehydraulic slip members 3140 to expand in the radial direction and gripthe interior surface of the casing 3075. The casing 3075 is thenpreferably maintained in a substantially stationary position.

[0822] The pressurization of the pressure chambers 3175 and 3190 causethe first upper sealing head 3030, first outer sealing mandrel 3040,second upper sealing head 3050, second outer sealing mandrel 3060, andexpansion cone 3070 to move in an axial direction relative to the casing3075. In this manner, the expansion cone 3070 will cause the casing 3075to expand in the radial direction, beginning with the lower end 3250 ofthe casing 3075.

[0823] During the radial expansion process, the casing 3075 is preventedfrom moving in an upward direction by the slips 3025. A length of thecasing 3075 is then expanded in the radial direction through thepressurization of the pressure chambers 3175 and 3190. The length of thecasing 3075 that is expanded during the expansion process will beproportional to the stroke length of the first upper sealing head 3030,first outer sealing mandrel 3040, second upper sealing head 3050, andexpansion cone 3070.

[0824] Upon the completion of a stroke, the operating pressure of thesecond fluidic material is reduced and the first upper sealing head3030, first outer sealing mandrel 3040, second upper sealing head 3050,second outer sealing mandrel 3060, and expansion cone 3070 drop to theirrest positions with the casing 3075 supported by the expansion cone3070. The reduction in the operating pressure of the second fluidicmaterial also causes the spring bias 3135 of the slips 3025 to pull theslip members 3140 away from the inside walls of the casing 3075.

[0825] The position of the drillpipe 3075 is preferably adjustedthroughout the radial expansion process in order to maintain theoverlapping relationship between the thin walled sections of the lowerend of the existing wellbore casing and the upper end of the casing3235. In a preferred embodiment, the stroking of the expansion cone 3070is then repeated, as necessary, until the thin walled section 3240 ofthe upper end 3235 of the casing 3075 is expanded into the thin walledsection of the lower end of the existing wellbore casing. In thismanner, a wellbore casing is formed including two adjacent sections ofcasing having a substantially constant inside diameter. This process maythen be repeated for the entirety of the wellbore to provide a wellborecasing thousands of feet in length having a substantially constantinside diameter.

[0826] In a preferred embodiment, during the final stroke of theexpansion cone 3070, the slips 3025 are positioned as close as possibleto the thin walled section 3240 of the upper end 3235 of the casing 3075in order minimize slippage between the casing 3075 and the existingwellbore casing at the end of the radial expansion process.Alternatively, or in addition, the outside diameter of the upper annularsealing member 3245 is selected to ensure sufficient interference fitwith the inside diameter of the lower end of the existing casing toprevent axial displacement of the casing 3075 during the final stroke.Alternatively, or in addition, the outside diameter of the lower annularsealing member 3260 is selected to provide an interference fit with theinside walls of the wellbore at an earlier point in the radial expansionprocess so as to prevent further axial displacement of the casing 3075.In this final alternative, the interference fit is preferably selectedto permit expansion of the casing 3075 by pulling the expansion cone3070 out of the wellbore, without having to pressurize the pressurechambers 3175 and 3190.

[0827] During the radial expansion process, the pressurized areas of theapparatus 3000 are preferably limited to the fluid passages 3080, 3085,3090, 3095, 3100, 3110, 3115, 3120, the pressure chambers 3130 withinthe slips 3025, and the pressure chambers 3175 and 3190. No fluidpressure acts directly on the casing 3075. This permits the use ofoperating pressures higher than the casing 3075 could normallywithstand.

[0828] Once the casing 3075 has been completely expanded off of theexpansion cone 3070, the remaining portions of the apparatus 3000 areremoved from the wellbore. In a preferred embodiment, the contactpressure between the deformed thin wall sections and compressibleannular members of the lower end of the existing casing and the upperend 3235 of the casing 3075 ranges from about 400 to 10,000 psi in orderto optimally support the casing 3075 using the existing wellbore casing.

[0829] In this manner, the casing 3075 is radially expanded into contactwith an existing section of casing by pressurizing the interior fluidpassages 3080, 3085, 3090, 3095, 3100, 3110, 3115, and 3120, thepressure chambers 3130 of the slips 3025 and the pressure chambers 3175and 3190 of the apparatus 3000.

[0830] In a preferred embodiment, as required, the annular body ofhardenable fluidic material is then allowed to cure to form a rigidouter annular body about the expanded casing 3075. In the case where thecasing 3075 is slotted, the cured fluidic material preferably permeatesand envelops the expanded casing 3075. The resulting new section ofwellbore casing includes the expanded casing 3075 and the rigid outerannular body. The overlapping joint between the pre-existing wellborecasing and the expanded casing 3075 includes the deformed thin wallsections and the compressible outer annular bodies. The inner diameterof the resulting combined wellbore casings is substantially constant. Inthis manner, a mono-diameter wellbore casing is formed. This process ofexpanding overlapping tubular members having thin wall end portions withcompressible annular bodies into contact can be repeated for the entirelength of a wellbore. In this manner, a mono-diameter wellbore casingcan be provided for thousands of feet in a subterranean formation.

[0831] In a preferred embodiment, as the expansion cone 3070 nears theupper end 3235 of the casing 3075, the operating flow rate of the secondfluidic material is reduced in order to minimize shock to the apparatus3000. In an alternative embodiment, the apparatus 3000 includes a shockabsorber for absorbing the shock created by the completion of the radialexpansion of the casing 3075.

[0832] In a preferred embodiment, the reduced operating pressure of thesecond fluidic material ranges from about 100 to 1,000 psi as theexpansion cone 3070 nears the end of the casing 3075 in order tooptimally provide reduced axial movement and velocity of the expansioncone 3070. In a preferred embodiment, the operating pressure of thesecond fluidic material is reduced during the return stroke of theapparatus 3000 to the range of about 0 to 500 psi in order minimize theresistance to the movement of the expansion cone 3070 during the returnstroke. In a preferred embodiment, the stroke length of the apparatus3000 ranges from about 10 to 45 feet in order to optimally provideequipment that can be easily handled by typical oil well riggingequipment and also minimize the frequency at which the apparatus 3000must be re-stroked.

[0833] In an alternative embodiment, at least a portion of one or bothof the upper sealing heads, 3030 and 3050, includes an expansion conefor radially expanding the casing 3075 during operation of the apparatus3000 in order to increase the surface area of the casing 3075 acted uponduring the radial expansion process. In this manner, the operatingpressures can be reduced.

[0834] Alternatively, the apparatus 3000 may be used to join a firstsection of pipeline to an existing section of pipeline. Alternatively,the apparatus 3000 may be used to directly line the interior of awellbore with a casing, without the use of an outer annular layer of ahardenable material. Alternatively, the apparatus 3000 may be used toexpand a tubular support member in a hole.

[0835] Referring now to FIG. 21, an apparatus 3330 for isolatingsubterranean zones will be described. A wellbore 3305 including a casing3310 are positioned in a subterranean formation 3315. The subterraneanformation 3315 includes a number of productive and non-productive zones,including a water zone 3320 and a targeted oil sand zone 3325. Duringexploration of the subterranean formation 3315, the wellbore 3305 may beextended in a well known manner to traverse the various productive andnon-productive zones, including the water zone 3320 and the targeted oilsand zone 3325.

[0836] In a preferred embodiment, in order to fluidicly isolate thewater zone 3320 from the targeted oil sand zone 3325, an apparatus 3330is provided that includes one or more sections of solid casing 3335, oneor more external seals 3340, one or more sections of slotted casing3345, one or more intermediate sections of solid casing 3350, and asolid shoe 3355.

[0837] The solid casing 3335 may provide a fluid conduit that transmitsfluids and other materials from one end of the solid casing 3335 to theother end of the solid casing 3335. The solid casing 3335 may compriseany number of conventional commercially available sections of solidtubular casing such as, for example, oilfield tubulars fabricated fromchromium steel or fiberglass. In a preferred embodiment, the solidcasing 3335 comprises oilfield tubulars available from various foreignand domestic steel mills.

[0838] The solid casing 3335 is preferably coupled to the casing 3310.The solid casing 3335 may be coupled to the casing 3310 using any numberof conventional commercially available processes such as, for example,welding, slotted and expandable connectors, or expandable solidconnectors. In a preferred embodiment, the solid casing 3335 is coupledto the casing 3310 by using expandable solid connectors. The solidcasing 3335 may comprise a plurality of such solid casings 3335.

[0839] The solid casing 3335 is preferably coupled to one more of theslotted casings 3345. The solid casing 3335 may be coupled to theslotted casing 3345 using any number of conventional commerciallyavailable processes such as, for example, welding, or slotted andexpandable connectors. In a preferred embodiment, the solid casing 3335is coupled to the slotted casing 3345 by expandable solid connectors.

[0840] In a preferred embodiment, the casing 3335 includes one morevalve members 3360 for controlling the flow of fluids and othermaterials within the interior region of the casing 3335. In analternative embodiment, during the production mode of operation, aninternal tubular string with various arrangements of packers, perforatedtubing, sliding sleeves, and valves may be employed within the apparatusto provide various options for commingling and isolating subterraneanzones from each other while providing a fluid path to the surface.

[0841] In a particularly preferred embodiment, the casing 3335 is placedinto the wellbore 3305 by expanding the casing 3335 in the radialdirection into intimate contact with the interior walls of the wellbore3305. The casing 3335 may be expanded in the radial direction using anynumber of conventional commercially available methods. In a preferredembodiment, the casing 3335 is expanded in the radial direction usingone or more of the processes and apparatus described within the presentdisclosure.

[0842] The seals 3340 prevent the passage of fluids and other materialswithin the annular region 3365 between the solid casings 3335 and 3350and the wellbore 3305. The seals 3340 may comprise any number ofconventional commercially available sealing materials suitable forsealing a casing in a wellbore such as, for example, lead, rubber orepoxy. In a preferred embodiment, the seals 3340 comprise Stratalokepoxy material available from Halliburton Energy Services.

[0843] The slotted casing 3345 permits fluids and other materials topass into and out of the interior of the slotted casing 3345 from and tothe annular region 3365. In this manner, oil and gas may be producedfrom a producing subterranean zone within a subterranean formation. Theslotted casing 3345 may comprise any number of conventional commerciallyavailable sections of slotted tubular casing. In a preferred embodiment,the slotted casing 3345 comprises expandable slotted tubular casingavailable from Petroline in Abeerdeen, Scotland. In a particularlypreferred embodiment, the slotted casing 145 comprises expandableslotted sandscreen tubular casing available from Petroline in Abeerdeen,Scotland.

[0844] The slotted casing 3345 is preferably coupled to one or moresolid casing 3335. The slotted casing 3345 may be coupled to the solidcasing 3335 using any number of conventional commercially availableprocesses such as, for example, welding, or slotted or solid expandableconnectors. In a preferred embodiment, the slotted casing 3345 iscoupled to the solid casing 3335 by expandable solid connectors.

[0845] The slotted casing 3345 is preferably coupled to one or moreintermediate solid casings 3350. The slotted casing 3345 may be coupledto the intermediate solid casing 3350 using any number of conventionalcommercially available processes such as, for example, welding orexpandable solid or slotted connectors. In a preferred embodiment, theslotted casing 3345 is coupled to the intermediate solid casing 3350 byexpandable solid connectors.

[0846] The last section of slotted casing 3345 is preferably coupled tothe shoe 3355. The last slotted casing 3345 may be coupled to the shoe3355 using any number of conventional commercially available processessuch as, for example, welding or expandable solid or slotted connectors.In a preferred embodiment, the last slotted casing 3345 is coupled tothe shoe 3355 by an expandable solid connector.

[0847] In an alternative embodiment, the shoe 3355 is coupled directlyto the last one of the intermediate solid casings 3350.

[0848] In a preferred embodiment, the slotted casings 3345 arepositioned within the wellbore 3305 by expanding the slotted casings3345 in a radial direction into intimate contact with the interior wallsof the wellbore 3305. The slotted casings 3345 may be expanded in aradial direction using any number of conventional commercially availableprocesses. In a preferred embodiment, the slotted casings 3345 areexpanded in the radial direction using one or more of the processes andapparatus disclosed in the present disclosure with reference to FIGS.14a-20.

[0849] The intermediate solid casing 3350 permits fluids and othermaterials to pass between adjacent slotted casings 3345. Theintermediate solid casing 3350 may comprise any number of conventionalcommercially available sections of solid tubular casing such as, forexample, oilfield tubulars fabricated from chromium steel or fiberglass.In a preferred embodiment, the intermediate solid casing 3350 comprisesoilfield tubulars available from foreign and domestic steel mills.

[0850] The intermediate solid casing 3350 is preferably coupled to oneor more sections of the slotted casing 3345. The intermediate solidcasing 3350 may be coupled to the slotted casing 3345 using any numberof conventional commercially available processes such as, for example,welding, or solid or slotted expandable connectors. In a preferredembodiment, the intermediate solid casing 3350 is coupled to the slottedcasing 3345 by expandable solid connectors. The intermediate solidcasing 3350 may comprise a plurality of such intermediate solid casing3350.

[0851] In a preferred embodiment, each intermediate solid casing 3350includes one more valve members 3370 for controlling the flow of fluidsand other materials within the interior region of the intermediatecasing 3350. In an alternative embodiment, as will be recognized bypersons having ordinary skill in the art and the benefit of the presentdisclosure, during the production mode of operation, an internal tubularstring with various arrangements of packers, perforated tubing, slidingsleeves, and valves may be employed within the apparatus to providevarious options for commingling and isolating subterranean zones fromeach other while providing a fluid path to the surface.

[0852] In a particularly preferred embodiment, the intermediate casing3350 is placed into the wellbore 3305 by expanding the intermediatecasing 3350 in the radial direction into intimate contact with theinterior walls of the wellbore 3305. The intermediate casing 3350 may beexpanded in the radial direction using any number of conventionalcommercially available methods.

[0853] In an alternative embodiment, one or more of the intermediatesolid casings 3350 may be omitted. In an alternative preferredembodiment, one or more of the slotted casings 3345 are provided withone or more seals 3340.

[0854] The shoe 3355 provides a support member for the apparatus 3330.In this manner, various production and exploration tools may besupported by the show 3350. The shoe 3350 may comprise any number ofconventional commercially available shoes suitable for use in a wellboresuch as, for example, cement filled shoe, or an aluminum or compositeshoe. In a preferred embodiment, the shoe 3350 comprises an aluminumshoe available from Halliburton. In a preferred embodiment, the shoe3355 is selected to provide sufficient strength in compression andtension to permit the use of high capacity production and explorationtools.

[0855] In a particularly preferred embodiment, the apparatus 3330includes a plurality of solid casings 3335, a plurality of seals 3340, aplurality of slotted casings 3345, a plurality of intermediate solidcasings 3350, and a shoe 3355. More generally, the apparatus 3330 maycomprise one or more solid casings 3335, each with one or more valvemembers 3360, n slotted casings 3345, n−1 intermediate solid casings3350, each with one or more valve members 3370, and a shoe 3355.

[0856] During operation of the apparatus 3330, oil and gas may becontrollably produced from the targeted oil sand zone 3325 using theslotted casings 3345. The oil and gas may then be transported to asurface location using the solid casing 3335. The use of intermediatesolid casings 3350 with valve members 3370 permits isolated sections ofthe zone 3325 to be selectively isolated for production. The seals 3340permit the zone 3325 to be fluidicly isolated from the zone 3320. Theseals 3340 further permits isolated sections of the zone 3325 to befluidicly isolated from each other. In this manner, the apparatus 3330permits unwanted and/or non-productive subterranean zones to befluidicly isolated.

[0857] In an alternative embodiment, as will be recognized by personshaving ordinary skill in the art and also having the benefit of thepresent disclosure, during the production mode of operation, an internaltubular string with various arrangements of packers, perforated tubing,sliding sleeves, and valves may be employed within the apparatus toprovide various options for commingling and isolating subterranean zonesfrom each other while providing a fluid path to the surface.

[0858] Referring to FIGS. 22a, 22 b, 22 c and 22 d, an embodiment of anapparatus 3500 for forming a wellbore casing while drilling a wellborewill now be described. In a preferred embodiment, the apparatus 3500includes a support member 3505, a mandrel 3510, a mandrel launcher 3515,a shoe 3520, a tubular member 3525, a mud motor 3530, a drill bit 3535,a first fluid passage 3540, a second fluid passage 3545, a pressurechamber 3550, a third fluid passage 3555, a cup seal 3560, a body oflubricant 3565, seals 3570, and a releasable coupling 3600.

[0859] The support member 3505 is coupled to the mandrel 3510. Thesupport member 3505 preferably comprises an annular member havingsufficient strength to carry and support the apparatus 3500 within thewellbore 3575. In a preferred embodiment, the support member 3505further includes one or more conventional centralizers (not illustrated)to help stabilize the apparatus 3500.

[0860] The support member 3505 may comprise one or more sections ofconventional commercially available tubular materials such as, forexample, oilfield country tubular goods, low alloy steel, stainlesssteel or carbon steel. In a preferred embodiment, the support member3505 comprises coiled tubing or drillpipe in order to optimally permitthe placement of the apparatus 3500 within a non-vertical wellbore.

[0861] In a preferred embodiment, the support member 3505 includes afirst fluid passage 3540 for conveying fluidic materials from a surfacelocation to the fluid passage 3545. In a preferred embodiment, the firstfluid passage 3540 is adapted to convey fluidic materials such as water,drilling mud, cement, epoxy or slag mix at operating pressures and flowrates ranging from about 0 to 10,000 psi and 0 to 3,000 gallons/minute.

[0862] The mandrel 3510 is coupled to and supported by the supportmember 3505. The mandrel 3510 is also coupled to and supports themandrel launcher 3515 and tubular member 3525. The mandrel 3510 ispreferably adapted to controllably expand in a radial direction. Themandrel 3510 may comprise any number of conventional commerciallyavailable mandrels modified in accordance with the teachings of thepresent disclosure. In a preferred embodiment, the mandrel 3510comprises a hydraulic expansion tool as disclosed in U.S. Pat. No.5,348,095, the contents of which are incorporated herein by reference,modified in accordance with the teachings of the present disclosure.

[0863] In a preferred embodiment, the mandrel 3510 includes one or moreconical sections for expanding the tubular member 3525 in the radialdirection. In a preferred embodiment, the outer surfaces of the conicalsections of the mandrel 3510 have a surface hardness ranging from about58 to 62 Rockwell C in order to optimally radially expand the tubularmember 3525.

[0864] In a preferred embodiment, the mandrel 3510 includes a secondfluid passage 3545 fluidicly coupled to the first fluid passage 3540 andthe pressure chamber 3550 for conveying fluidic materials from the firstfluid passage 3540 to the pressure chamber 3550. In a preferredembodiment, the second fluid passage 3545 is adapted to convey fluidicmaterials such as water, drilling mud, cement, epoxy or slag mix atoperating pressures and flow rates ranging from about 0 to 12,000 psiand 0 to 3,500 gallons/minute in order to optimally provide operatingpressure for efficient operation.

[0865] The mandrel launcher 3515 is coupled to the tubular member 3525,the mandrel 3510, and the shoe 3520. The mandrel launcher 3515preferably comprises a tapered annular member that mates with at aportion of at least one of the conical portions of the outer surface ofthe mandrel 3510. In a preferred embodiment, the wall thickness of themandrel launcher is less than the wall thickness of the tubular member3525 in order to facilitate the initiation of the radial expansionprocess and facilitate the placement of the apparatus in openings havingtight clearances. In a preferred embodiment, the wall thickness of themandrel launcher 3515 ranges from about 50 to 100% of the wall thicknessof the tubular member 3525 immediately adjacent to the mandrel launcher3515 in order to optimally faciliate the radial expansion process andfacilitate the insertion of the apparatus 3500 into wellbore casings andother areas with tight clearances.

[0866] The mandrel launcher 3515 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low alloy steel, carbon steel orstainless steel. In a preferred embodiment, the mandrel launcher 3515 isfabricated from oilfield country tubular goods of higher strength bylower wall thickness than the tubular member 3525 in order to optimallyprovide a smaller container having approximately the same burst strengthas the tubular member 3525.

[0867] The shoe 3520 is coupled to the mandrel launcher 3515 and thereleasable coupling 3600. The shoe 3520 preferably comprises asubstantially annular member. In a preferred embodiment, the shoe 3520or the releasable coupling 3600 include a third fluid passage 3555fluidicly coupled to the pressure chamber 3550 and the mud motor 3530.

[0868] The shoe 3520 may comprise any number of conventionalcommercially available shoes such as, for example, cement filled,aluminum or composite modified in accordance with the teachings of thepresent disclosure. In a preferred embodiment, the shoe 3520 comprises ahigh strength shoe having a burst strength approximately equal to theburst strength of the tubular member 3525 and mandrel launcher 3515. Theshoe 3520 is preferably coupled to the mud motor 3520 by a releasablecoupling 3600 in order to optimally provide for removal of the mud motor3530 and drill nit 3535 upon the completion of a drilling and casingoperation.

[0869] In a preferred embodiment, the shoe 3520 includes a releasablelatch mechanism 3600 for retrieving and removing the mud motor 3530 anddrill bit 3535 upon the completion of the drilling and casing formationoperations. In a preferred embodiment, the shoe 3520 further includes ananti-rotation device for maintaining the shoe 3520 in a substantiallystationary rotational position during operation of the apparatus 3500.In a preferred embodiment, the releasable latch mechanism 3600 isreleasably coupled to the shoe 3520.

[0870] The tubular member 3525 is supported by and coupled to themandrel 3510. The tubular member 3525 is expanded in the radialdirection and extruded off of the mandrel 3510. The tubular member 3525may be fabricated from any number of conventional commercially availablematerials such as, for example, Oilfield Country Tubular Goods (OCTG),13 chromium steel tubing/casing, automotive grade steel, or plastictubing/casing. In a preferred embodiment, the tubular member 3525 isfabricated from OCTG in order to maximize strength after expansion. Theinner and outer diameters of the tubular member 3525 may range, forexample, from approximately 0.75 to 47 inches and 1.05 to 48 inches,respectively. In a preferred embodiment, the inner and outer diametersof the tubular member 3525 range from about 3 to 15.5 inches and 3.5 to16 inches, respectively in order to optimally provide minimaltelescoping effect in the most commonly drilled wellbore sizes. Thetubular member 3525 preferably comprises an annular member with solidwalls.

[0871] In a preferred embodiment, the upper end portion 3580 of thetubular member 3525 is slotted, perforated, or otherwise modified tocatch or slow down the mandrel 3510 when the mandrel 3510 completes theextrusion of tubular member 3525. For typical tubular member 3525materials, the length of the tubular member 3525 is preferably limitedto between about 40 to 20,000 feet in length. The tubular member 3525may comprise a single tubular member or, alternatively, a plurality oftubular members coupled to one another.

[0872] The mud motor 3530 is coupled to the shoe 3520 and the drill bit3535. The mud motor 3530 is also fluidicly coupled to the fluid passage3555. In a preferred embodiment, the mud motor 3530 is driven by fluidicmaterials such as, for example, drilling mud, water, cement, epoxy,lubricants or slag mix conveyed from the fluid passage 3555 to the mudmotor 3530. In this manner, the mud motor 3530 drives the drill bit3535. The operating pressures and flow rates for operating mud motor3530 may range, for example, from about 0 to 12,000 psi and 0 to 10,000gallons/minute. In a preferred embodiment, the operating pressures andflow rates for operating mud motor 3530 range from about 0 to 5,000 psiand 40 to 3,000 gallons/minute.

[0873] The mud motor 3530 may comprise any number of conventionalcommercially available mud motors, modified in accordance with theteachings of the present disclosure. In a preferred embodiment, the sizeof the mud motor 3520 and drill bit 3535 are selected to pass throughthe interior of the shoe 3520 and the expanded tubular member 3525. Inthis manner, the mud motor 3520 and drill bit 3535 may be retrieved fromthe downhole location upon the conclusion of the drilling and casingoperations.

[0874] The drill bit 3535 is coupled to the mud motor 3530. The drillbit 3535 is preferably adapted to be powered by the mud motor 3530. Inthis manner, the drill bit 3535 drills out new sections of the wellbore3575.

[0875] The drill bit 3535 may comprise any number of conventionalcommercially available drill bits, modified in accordance with theteachings of the present disclosure. In a preferred embodiment, the sizeof the mud motor 3520 and drill bit 3535 are selected to pass throughthe interior of the shoe 3520 and the expanded tubular member 3525. Inthis manner, the mud motor 3520 and drill bit 3535 may be retrieved fromthe downhole location upon the conclusion of the drilling and casingoperations. In several alternative preferred embodiments, the drill bit3535 comprises an eccentric drill bit, a bi-centered drill bit, or asmall diameter drill bit with an hydraulically actuated under reamer.

[0876] The first fluid passage 3540 permits fluidic materials to betransported to the second fluid passage 3545, the pressure chamber 3550,the third fluid passage 3555, and the mud motor 3530. The first fluidpassage 3540 is coupled to and positioned within the support member3505. The first fluid passage 3540 preferably extends from a positionadjacent to the surface to the second fluid passage 3545 within themandrel 3510. The first fluid passage 3540 is preferably positionedalong a centerline of the apparatus 3500.

[0877] The second fluid passage 3545 permits fluidic materials to beconveyed from the first fluid passage 3540 to the pressure chamber 3550,the third fluid passage 3555, and the mud motor 3530. The second fluidpassage 3545 is coupled to and positioned within the mandrel 3510. Thesecond fluid passage 3545 preferably extends from a position adjacent tothe first fluid passage 3540 to the bottom of the mandrel 3510. Thesecond fluid passage 3545 is preferably positioned substantially alongthe centerline of the apparatus 3500.

[0878] The pressure chamber 3550 permits fluidic materials to beconveyed from the second fluid passage 3545 to the third fluid passage3555, and the mud motor 3530. The pressure chamber is preferably definedby the region below the mandrel 3510 and within the tubular member 3525,mandrel launcher 3515, shoe 3520, and releasable coupling 3600. Duringoperation of the apparatus 3500, pressurization of the pressure chamber3550 preferably causes the tubular member 3525 to be extruded off of themandrel 3510.

[0879] The third fluid passage 3555 permits fluidic materials to beconveyed from the pressure chamber 3550 to the mud motor 3530. The thirdfluid passage 3555 may be coupled to and positioned within the shoe 3520or releasable coupling 3600. The third fluid passage 3555 preferablyextends from a position adjacent to the pressure chamber 3550 to thebottom of the shoe 3520 or releasable coupling 3600. The third fluidpassage 3555 is preferably positioned substantially along the centerlineof the apparatus 3500.

[0880] The fluid passages 3540, 3545, and 3555 are preferably selectedto convey materials such as cement, drilling mud or epoxies at flowrates and pressures ranging from about 0 to 3,000 gallons/minute and 0to 9,000 psi in order to optimally operational efficiency.

[0881] The cup seal 3560 is coupled to and supported by the outersurface of the support member 3505. The cup seal 3560 prevents foreignmaterials from entering the interior region of the tubular member 3525.The cup seal 3560 may comprise any number of conventional commerciallyavailable cup seals such as, for example, TP cups or SIP cups modifiedin accordance with the teachings of the present disclosure. In apreferred embodiment, the cup seal 3560 comprises a SIP cup, availablefrom Halliburton Energy Services in Dallas, Tex. in order to optimallyblock the entry of foreign materials and contain a body of lubricant. Ina preferred embodiment, the apparatus 3500 includes a plurality of suchcup seals in order to optimally prevent the entry of foreign materialinto the interior region of the tubular member 3525 in the vicinity ofthe mandrel 3510.

[0882] In a preferred embodiment, a quantity of lubricant 3565 isprovided in the annular region above the mandrel 3510 within theinterior of the tubular member 3525. In this manner, the extrusion ofthe tubular member 3525 off of the mandrel 3510 is facilitated. Thelubricant 3565 may comprise any number of conventional commerciallyavailable lubricants such as, for example, Lubriplate, chlorine basedlubricants, oil based lubricants or Climax 1500 Antisieze (3100). In apreferred embodiment, the lubricant 3565 comprises Climax 1500 Antisieze(3100) available from Climax Lubricants and Equipment Co. in Houston,Tex. in order to optimally provide optimum lubrication to faciliate theexpansion process.

[0883] The seals 3570 are coupled to and supported by the end portion3580 of the tubular member 3525. The seals 3570 are further positionedon an outer surface of the end portion 3580 of the tubular member 3525.The seals 3570 permit the overlapping joint between the lower endportion 3585 of a preexisting section of casing 3590 and the end portion3580 of the tubular member 3525 to be fluidicly sealed. The seals 3570may comprise any number of conventional commercially available sealssuch as, for example, lead, rubber, Teflon, or epoxy seals modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the seals 3570 are molded from Stratalock epoxy availablefrom Halliburton Energy Services in Dallas, Tex. in order to optimallyprovide a load bearing interference fit between the end 3580 of thetubular member 3525 and the end 3585 of the pre-existing casing 3590.

[0884] In a preferred embodiment, the seals 3570 are selected tooptimally provide a sufficient frictional force to support the expandedtubular member 3525 from the pre-existing casing 3590. In a preferredembodiment, the frictional force optimally provided by the seals 3570ranges from about 1,000 to 1,000,000 lbf in order to optimally supportthe expanded tubular member 3525.

[0885] The releasable coupling 3600 is preferably releasably coupled tothe bottom of the shoe 3520. In a preferred embodiment, the releasablecoupling 3600 includes fluidic seals for sealing the interface betweenthe releasable coupling 3600 and the shoe 3520. In this manner, thepressure chamber 3550 may be pressurized. The releasable coupling 3600may comprise any number of conventional commercially availablereleasable couplings suitable for drilling operations modified inaccordance with the teachings of the present disclosure.

[0886] As illustrated in FIG. 22A, during operation of the apparatus3500, the apparatus 3500 is preferably initially positioned within apreexisting section of a wellbore 3575 including a preexisting sectionof wellbore casing 3590. In a preferred embodiment, the upper endportion 3580 of the tubular member 3525 is positioned in an overlappingrelationship with the lower end 3585 of the preexisting section ofcasing 3590. In a preferred embodiment, the apparatus 3500 is initiallypositioned in the wellbore 3575 with the drill bit 353 in contact withthe bottom of the wellbore 3575. During the initial placement of theapparatus 3500 in the wellbore 3575, the tubular member 3525 ispreferably supported by the mandrel 3510.

[0887] As illustrated in FIG. 22B, a fluidic material 3595 is thenpumped into the first fluid passage 3540. The fluidic material 3595 ispreferably conveyed from the first fluid passage 3540 to the secondfluid passage 3545, the pressure chamber 3550, the third fluid passage3555 and the inlet to the mud motor 3530. The fluidic material 3595 maycomprise any number of conventional commercially available fluidicmaterials such as, for example, drilling mud, water, cement, epoxy orslag mix. The fluidic material 3595 may be pumped into the first fluidpassage 3540 at operating pressures and flow rates ranging, for example,from about 0 to 9,000 psi and 0 to 3,000 gallons/minute.

[0888] The fluidic material 3595 will enter the inlet for the mud motor3530 and drive the mud motor 3530. The fluidic material 3595 will thenexit the mud motor 3530 and enter the annular region surrounding theapparatus 3500 within the wellbore 3575. The mud motor 3530 will in turndrive the drill bit 3535. The operation of the drill bit 3535 will drillout a new section of the wellbore 3575.

[0889] In the case where the fluidic material 3595 comprises ahardenable fluidic material, the fluidic material 3595 preferably ispermitted to cure and form an outer annular body surrounding theperiphery of the expanded tubular member 3525. Alternatively, in thecase where the fluidic material 3595 is a non-hardenable fluidicmaterial, the tubular member 3595 preferably is expanded into intimatecontact with the interior walls of the wellbore 3575. In this manner, anouter annular body is not provided in all applications.

[0890] As illustrated in FIG. 22C, at some point during operation of themud motor 3530 and drill bit 3535, the pressure drop across the mudmotor 3530 will create sufficient back pressure to cause the operatingpressure within the pressure chamber 3550 to elevate to the pressurenecessary to extrude the tubular member 3525 off of the mandrel 3510.The elevation of the operating pressure within the pressure chamber 3550will then cause the tubular member 3525 to extrude off of the mandrel3510 as illustrated in FIG. 22D. For typical tubular members 3525, thenecessary operating pressure may range, for example, from about 1,000 to9,000 psi. In this manner, a wellbore casing is formed simultaneous withthe drilling out of a new section of wellbore.

[0891] In a particularly preferred embodiment, during the operation ofthe apparatus 3500, the apparatus 3500 is lowered into the wellbore 3575until the drill bit 3535 is proximate the bottom of the wellbore 3575.Throughout this process, the tubular member 3525 is preferably supportedby the mandrel 3510. The apparatus 3500 is then lowered until the drillbit 3535 is placed in contact with the bottom of the wellbore 3575. Atthis point, at least a portion of the weight of the tubular member 3525is supported by the drill bit 3535.

[0892] The fluidic material 3595 is then pumped into the first fluidpassage 3540, second fluid passage 3545, pressure chamber 3550, thirdfluid passage 3555, and the inlet of the mud motor 3530. The mud motor3530 then drives the drill bit 3535 to drill out a new section of thewellbore 3575. Once the differential pressure across the mud motor 3530exceeds the minimum extrusion pressure for the tubular member 3525, thetubular member 3525 begins to extrude off of the mandrel 3510. As thetubular member 3525 is extruded off of the mandrel 3510, the weight ofthe extruded portion of the tubular member 3525 is transferred to andsupported by the drill bit 3535. In a preferred embodiment, the pumpingpressure of the fluidic material 3595 is maintained substantiallyconstant throughout this process. At some point during the process ofextruding the tubular member 3525 off of the mandrel 3510, a sufficientportion of the weight of the tubular member 3525 is transferred to thedrill bit 3535 to stop the extrusion process due to the opposing force.Continued drilling by the drill bit 3535 eventually transfers asufficient portion of the weight of the extruded portion of the tubularmember 3525 back to the mandrel 3510. At this point, the extrusion ofthe tubular member 3525 off of the mandrel 3510 continues. In thismanner, the support member 3505 never has to be moved and no drillpipeconnections have to be made at the surface since the new section of thewellbore casing within the newly drilled section of wellbore is createdby the constant downward feeding of the expanded tubular member 3525 offof the mandrel 3510.

[0893] Once the new section of wellbore that is lined with the fullyexpanded tubular member 3525 is completed, the support member 3505 andmandrel 3510 are removed from the wellbore 3575. The drilling assemblyincluding the mud motor 3530 and drill bit 3535 are then preferablyremoved by lowering a drillstring into the new section of wellborecasing and retrieving the drilling assembly by using the latch 3600. Theexpanded tubular member 3525 is then cemented using conventional squeezecementing methods to provide a solid annular sealing member around theperiphery of the expanded tubular member 3525.

[0894] Alternatively, the apparatus 3500 may be used to repair or forman underground pipeline or form a support member for a structure. Inseveral preferred alternative embodiments, the teachings of theapparatus 3500 are combined with the teachings of the embodimentsillustrated in FIGS. 1-21. For example, by operably coupling the mudmotor 3530 and drill bit 3535 to the pressure chambers used to cause theradial expansion of the tubular members of the embodiments illustratedand described with reference to FIGS. 1-21, the use of plugs may beeliminated and radial expansion of tubular members can be combined withthe drilling out of new sections of wellbore.

[0895] Referring now to FIGS. 23A, 23B and 23C, an apparatus 3700 forexpanding a tubular member will be described. In a preferred embodiment,the apparatus 3700 includes a support member 3705, a packer 3710, afirst fluid conduit 3715, an annular fluid passage 3720, fluid inlets3725, an annular seal 3730, a second fluid conduit 3735, a fluid passage3740, a mandrel 3745, a mandrel launcher 3750, a tubular member 3755,slips 3760, and seals 3765. In a preferred embodiment, the apparatus3700 is used to radially expand the tubular member 3755. In this manner,the apparatus 3700 may be used to form a wellbore casing, line awellbore casing, form a pipeline, line a pipeline, form a structuralsupport member, or repair a wellbore casing, pipeline or structuralsupport member. In a preferred embodiment, the apparatus 3700 is used toclad at least a portion of the tubular member 3755 onto a preexistingtubular member.

[0896] The support member 3705 is preferably coupled to the packer 3710and the mandrel launcher 3750. The support member 3705 preferablycomprises a tubular member fabricated from any number of conventionalcommercially available materials such as, for example, oilfield countrytubular goods, low alloy steel, carbon steel, or stainless steel. Thesupport member 3705 is preferably selected to fit through a preexistingsection of wellbore casing 3770. In this manner, the apparatus 3700 maybe positioned within the wellbore casing 3770. In a preferredembodiment, the support member 3705 is releasably coupled to the mandrellauncher 3750. In this manner, the support member 3705 may be decoupledfrom the mandrel launcher 3750 upon the completion of an extrusionoperation.

[0897] The packer 3710 is coupled to the support member 3705 and thefirst fluid conduit 3715. The packer 3710 preferably provides a fluidseal between the outside surface of the first fluid conduit 3715 and theinside surface of the support member 3705. In this manner, the packer3710 preferably seals off and, in combination with the support member3705, first fluid conduit 3715, second fluid conduit 3735, and mandrel3745, defines an annular chamber 3775. The packer 3710 may comprise anynumber of conventional commercially available packers modified inaccordance with the teachings of the present disclosure.

[0898] The first fluid conduit 3715 is coupled to the packer 3710 andthe annular seal 3730. The first fluid conduit 3715 preferably comprisesan annular member fabricated from any number of conventionalcommercially available materials such as, for example, oilfield countrytubular goods, low alloy steel, carbon steel, or stainless steel. In apreferred embodiment, the first fluid conduit 3715 includes one or morefluid inlets 3725 for conveying fluidic materials from the annular fluidpassage 3720 into the chamber 3775.

[0899] The annular fluid passage 3720 is defined by and positionedbetween the interior surface of the first fluid conduit 3715 and theinterior surface of the second fluid conduit 3735. The annular fluidpassage 3720 is preferably adapted to convey fluidic materials such ascement, water, epoxy, lubricants, and slag mix at operating pressuresand flow rates ranging from about 0 to 9,000 psi and 0 to 3,000gallons/minute in order to optimally provide operational efficiency.

[0900] The fluid inlets 3725 are positioned in an end portion of thefirst fluid conduit 3715. The fluid inlets 3725 preferably are adaptedto convey fluidic materials such as cement, water, epoxy, lubricants,and slag mix at operating pressures and flow rates ranging from about 0to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provideoperational efficiency.

[0901] The annular seal 3730 is coupled to the first fluid conduit 3715and the second fluid conduit 3735. The annular seal 3730 preferablyprovides a fluid seal between the interior surface of the first fluidconduit 3715 and the exterior surface of the second fluid conduit 3735.The annular seal 3730 preferably provides a fluid seal between theinterior surface of the first fluid conduit 3715 and the exteriorsurface of the second fluid conduit 3735 during relative axial motion ofthe first fluid conduit 3715 and the second fluid conduit 3735. Theannular seal 3730 may comprise any number of conventional commerciallyavailable seals such as, for example, o-rings, polypak seals or metalspring energized seals. In a preferred embodiment, the annular seal 3730comprises a polypak seal available from Parker Seals in order tooptimally provide sealing for axial motion.

[0902] The second fluid conduit 3735 is coupled to the annular seal 3730and the mandrel 3745. The second fluid conduit preferably comprises atubular member fabricated from any number of conventional commerciallyavailable materials such as, for example, coiled tubing, oilfieldcountry tubular goods, low alloy steel, stainless steel, or low carbonsteel. In a preferred embodiment, the second fluid conduit 3735 isadapted to convey fluidic materials such as cement, water, epoxy,lubricants, and slag mix at operating pressures and flow rates rangingfrom about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order tooptimally provide operational efficiency.

[0903] The fluid passage 3740 is coupled to the second fluid conduit3735 and the mandrel 3745. In a preferred embodiment, the fluid passage3740 is adapted to convey fluidic materials such as cement, water,epoxy, lubricants, and slag mix at operating pressures and flow ratesranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in orderto optimally provide operational efficiency.

[0904] The mandrel 3745 is coupled to the second fluid conduit 3735 andthe mandrel launcher 3750. The mandrel 3745 preferably comprise anannular member having a conic section fabricated from any number ofconventional commercially available materials such as, for example,carbon steel, tool steel, ceramics, or composite materials. In apreferred embodiment, the angle of attack the conic section of themandrel 3745 ranges from about 10 to 30 degrees in order to optimallyexpand the mandrel launcher 3750 and tubular member 3755 in the radialdirection. In a preferred embodiment, the surface hardness of the conicsection of the mandrel 3745 ranges from about 50 Rockwell C to 70Rockwell C. In a particularly preferred embodiment, the surface hardnessof the outer surface of the conic section of the mandrel 3745 rangesfrom about 58 Rockwell C to 62 Rockwell C in order to optimally providehigh yield strength. In an alternative embodiment, the mandrel 3745 isexpandable in order to further optimally augment the radial expansionprocess.

[0905] The mandrel launcher 3750 is coupled to the support member 3705,the mandrel 3745, and the tubular member 3755. The mandrel launcher 3750preferably comprise a tubular member having a variable cross-section anda reduced wall thickness in order to facilitate the radial expansionprocess. In a preferred embodiment, the cross-sectional area of themandrel launcher 3750 at one end is adapted to mate with the mandrel3745, and at the other end, the cross-sectional area of the mandrellauncher 3750 is adapted to match the cross-sectional area of thetubular member 3755. In a preferred embodiment, the wall thickness ofthe mandrel launcher 3750 ranges from about 50 to 100% of the wallthickness of the tubular member 3755 in order to facilitate theinitiation of the radial expansion process.

[0906] The mandrel launcher 3750 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low allow steel, stainless steel, orcarbon steel. In a preferred embodiment, the mandrel launcher 3750 isfabricated from oilfield country tubular goods having higher strengthbut lower wall thickness than the tubular member 3755 in order tooptimally match the burst strength of the tubular member 3755. In apreferred embodiment, the mandrel launcher 3750 is removably coupled tothe tubular member 3755. In this manner, the mandrel launcher 3750 maybe removed from the wellbore 3780 upon the completion of an extrusionoperation.

[0907] The tubular member 3755 is coupled to the mandrel launcher, theslips 3760 and the seals 3765. The tubular member 3755 preferablycomprises a tubular member fabricated from any number of conventionalcommercially available materials such as, for example, low alloy steel,carbon steel, stainless steel, or oilfield country tubular goods. In apreferred embodiment, the tubular member 3755 is fabricated fromoilfield country tubular goods.

[0908] The slips 3760 are coupled to the outside surface of the tubularmember 3755. The slips 3760 preferably are adapted to couple to theinterior walls of a casing, pipeline or other structure upon the radialexpansion of the tubular member 3755. In this manner, the slips 3760provide structural support for the expanded tubular member 3755. Theslips 3760 may comprise any number of conventional commerciallyavailable slips, modified in accordance with the teachings of thepresent disclosure.

[0909] The seals 3765 are coupled to the outside surface of the tubularmember 3755. The seals 3765 preferably provide a fluidic seal betweenthe outside surface of the expanded tubular member 3755 and the interiorwalls of a casing, pipeline or other structure upon the radial expansionof the tubular member 3755. In this manner, the seals 3765 provide afluidic seal for the expanded tubular member 3755. The seals 3765 maycomprise any number of conventional commercially available seals suchas, for example, lead, rubber, Teflon or epoxy seals modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the seals 3765 comprise seals molded from Stratalock epoxyavailable from Halliburton Energy Services in Dallas, Tex. in order tooptimally provide a hydraulic seal in the overlapping joint andoptimally provide load carrying capacity to withstand the range oftypical tensile and compressive loads.

[0910] During operation of the apparatus 3700, the apparatus 3700 ispreferably lowered into a wellbore 3780 having a preexisting section ofwellbore casing 3770. In a preferred embodiment, the apparatus 3700 ispositioned with at least a portion of the tubular member 3755overlapping with a portion of the wellbore casing 3770. In this manner,the radial expansion of the tubular member 3755 will preferably causethe outside surface of the expanded tubular member 3755 to couple withthe inside surface of the wellbore casing 3770. In a preferredembodiment, the radial expansion of the tubular member 3755 will alsocause the slips 3760 and seals 3765 to engage with the interior surfaceof the wellbore casing 3770. In this manner, the expanded tubular member3755 is provided with enhanced structural support by the slips 3760 andan enhanced fluid seal by the seals 3765.

[0911] As illustrated in FIG. 23B, after placement of the apparatus 3700in an overlapping relationship with the wellbore casing 3770, a fluidicmaterial 3785 is preferably pumped into the chamber 3775 using the fluidpassage 3720 and the inlet passages 3725. In a preferred embodiment, thefluidic material is pumped into the chamber 3775 at operating pressuresand flow rates ranging from about 0 to 9,000 psi and 0 to 3,000gallons/minute in order to optimally provide operational efficiency. Thepumped fluidic material 3785 increase the operating pressure within thechamber 3775. The increased operating pressure in the chamber 3775 thencauses the mandrel 3745 to extrude the mandrel launcher 3750 and tubularmember 3755 off of the face of the mandrel 3745. The extrusion of themandrel launcher 3750 and tubular member 3755 off of the face of themandrel 3745 causes the mandrel launcher 3750 and tubular member 3755 toexpand in the radial direction. Continued pumping of the fluidicmaterial 3785 preferably causes the entire length of the tubular member3755 to expand in the radial direction.

[0912] In a preferred embodiment, the pumping rate and pressure of thefluidic material 3785 is reduced during the latter stages of theextrusion process in order to minimize shock to the apparatus 3700. In apreferred embodiment, the apparatus 3700 includes shock absorbers forabsorbing the shock caused by the completion of the extrusion process.

[0913] In a preferred embodiment, the extrusion process causes themandrel 3745 to move in an axial direction 3785. During the axialmovement of the mandrel, in a preferred embodiment, the fluid passage3740 conveys fluidic material 3790 displaced by the moving mandrel 3745out of the wellbore 3780. In this manner, the operational efficiency andspeed of the extrusion process is enhanced.

[0914] In a preferred embodiment, the extrusion process includes theinjection of a hardenable fluidic material into the annular regionbetween the tubular member 3755 and the bore hole 3780. In this manner,a hardened sealing layer is provided between the expanded tubular member3755 and the interior walls of the wellbore 3780.

[0915] As illustrated in FIG. 23C, in a preferred embodiment, upon thecompletion of the extrusion process, the support member 3705, packer3710, first fluid conduit 3715, annular seal 3730, second fluid conduit3735, mandrel 3745, and mandrel launcher 3750 are moved from thewellbore 3780.

[0916] In an alternative embodiment, the apparatus 3700 is used torepair a preexisting wellbore casing, pipeline, or structural support.In this alternative embodiment, both ends of the tubular member 3755preferably include slips 3760 and seals 3765.

[0917] In an alternative embodiment, the apparatus 3700 is used to forma tubular structural support for a building or offshore structure.

[0918] Referring now to FIGS. 24A, 24B, 24C, 24D, and 24E, an apparatus3900 for expanding a tubular member will be described. In a preferredembodiment, the apparatus 3900 includes a support member 3905, a mandrellauncher 3910, a mandrel 3915, a first fluid passage 3920, a tubularmember 3925, slips 3930, seals 3935, a shoe 3940, and a second fluidpassage 3945. In a preferred embodiment, the apparatus 3900 is used toradially expand the mandrel launcher 3910 and tubular member 3925. Inthis manner, the apparatus 3900 may be used to form a wellbore casing,line a wellbore casing, form a pipeline, line a pipeline, form astructural support member, or repair a wellbore casing, pipeline orstructural support member. In a preferred embodiment, the apparatus 3900is used to clad at least a portion of the tubular member 3925 onto apreexisting structural member.

[0919] The support member 3905 is preferably coupled to the mandrellauncher 3910. The support member 3905 preferably comprises a tubularmember fabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, or stainless steel. The support member 3905,the mandrel launcher 3910, the tubular member 3925, and the shoe 3940are preferably selected to fit through a preexisting section of wellborecasing 3950. In this manner, the apparatus 3900 may be positioned withinthe wellbore casing 3970. In a preferred embodiment, the support member3905 is releasably coupled to the mandrel launcher 3910. In this manner,the support member 3905 may be decoupled from the mandrel launcher 3910upon the completion of an extrusion operation.

[0920] The mandrel launcher 3910 is coupled to the support member 3905and the tubular member 3925. The mandrel launcher 3910 preferablycomprise a tubular member having a variable cross-section and a reducedwall thickness in order to facilitate the radial expansion process. In apreferred embodiment, the cross-sectional area of the mandrel launcher3910 at one end is adapted to mate with the mandrel 3915, and at theother end, the cross-sectional area of the mandrel launcher 3910 isadapted to match the cross-sectional area of the tubular member 3925. Ina preferred embodiment, the wall thickness of the mandrel launcher 3910ranges from about 50 to 100% of the wall thickness of the tubular member3925 in order to facilitate the initiation of the radial expansionprocess.

[0921] The mandrel launcher 3910 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low allow steel, stainless steel, orcarbon steel. In a preferred embodiment, the mandrel launcher 3910 isfabricated from oilfield country tubular goods having higher strengthbut lower wall thickness than the tubular member 3925 in order tooptimally match the burst strength of the tubular member 3925. In apreferred embodiment, the mandrel launcher 3910 is removably coupled tothe tubular member 3925. In this manner, the mandrel launcher 3910 maybe removed from the wellbore 3960 upon the completion of an extrusionoperation.

[0922] The mandrel 3915 is coupled to the mandrel launcher 3910. Themandrel 3915 preferably comprise an annular member having a conicsection fabricated from any number of conventional commerciallyavailable materials such as, for example, tool steel, carbon steel,ceramics, or composite materials. In a preferred embodiment, the angleof attack of the conic section of the mandrel 3915 ranges from about 10to 30 degrees in order to optimally expand the mandrel launcher 3910 andthe tubular member 3925 in the radial direction. In a preferredembodiment, the surface hardness of the conic section of the mandrel3915 ranges from about 58 to 62 Rockwell C in order to optimally providehigh strength and resist wear and galling. In an alternative embodiment,the mandrel 3915 is expandable in order to further optimally augment theradial expansion process.

[0923] The fluid passage 3920 is positioned within the mandrel 3915. Thefluid passage 3920 is preferably adapted to convey fluidic materialssuch as cement, water, epoxy, lubricants, and slag mix at operatingpressures and flow rates ranging from about 0 to 9,000 psi and 0 to3,000 gallons/minute in order to optimally provide operationalefficiency. The fluid passage 3920 preferably includes an inlet 3965adapted to receive a plug, or other similar device. In this manner, theinterior chamber 3970 above the mandrel 3915 may be fluidicly isolatedfrom the interior chamber 3975 below the mandrel 3915.

[0924] The tubular member 3925 is coupled to the mandrel launcher 3910,the slips 3930 and the seals 3935. The tubular member 3925 preferablycomprises a tubular member fabricated from any number of conventionalcommercially available materials such as, for example, low alloy steel,carbon steel, stainless steel, or oilfield country tubular goods. In apreferred embodiment, the tubular member 3925 is fabricated fromoilfield country tubular goods.

[0925] The slips 3930 are coupled to the outside surface of the tubularmember 3925. The slips 3930 preferably are adapted to couple to theinterior walls of a casing, pipeline or other structure upon the radialexpansion of the tubular member 3925. In this manner, the slips 3930provide structural support for the expanded tubular member 3925. Theslips 3930 may comprise any number of conventional commerciallyavailable slips, modified in accordance with the teachings of thepresent disclosure.

[0926] The seals 3935 are coupled to the outside surface of the tubularmember 3925. The seals 3935 preferably provide a fluidic seal betweenthe outside surface of the expanded tubular member 3925 and the interiorwalls of a casing, pipeline or other structure upon the radial expansionof the tubular member 3925. In this manner, the seals 3935 provide afluidic seal for the expanded tubular member 3925. The seals 3935 maycomprise any number of conventional commercially available seals suchas, for example, lead, rubber or epoxy. In a preferred embodiment, theseals 3935 comprise Stratalok epoxy material available from HalliburtonEnergy Services in order to optimally provide structural support for thetypical tensile and compressive loads.

[0927] The shoe 3940 is coupled to the tubular member 3925. The shoe3940 preferably comprises a substantially tubular member having a fluidpassage 3945 for conveying fluidic materials from the chamber 3975 tothe annular region 3970 outside of the apparatus 3900. The shoe 3940 maycomprise any number of conventional commercially available shoesmodified in accordance with the teachings of the present disclosure.

[0928] During operation of the apparatus 3900, the apparatus 3900 ispreferably lowered into a wellbore 3960 having a preexisting section ofwellbore casing 3975. In a preferred embodiment, the apparatus 3900 ispositioned with at least a portion of the tubular member 3925overlapping with a portion of the wellbore casing 3975. In this manner,the radial expansion of the tubular member 3925 will preferably causethe outside surface of the expanded tubular member 3925 to couple withthe inside surface of the wellbore casing 3975. In a preferredembodiment, the radial expansion of the tubular member 3925 will alsocause the slips 3930 and seals 3935 to engage with the interior surfaceof the wellbore casing 3975. In this manner, the expanded tubular member3925 is provided with enhanced structural support by the slips 3930 andan enhanced fluid seal by the seals 3935.

[0929] As illustrated in FIG. 24B, after placement of the apparatus 3900in an overlapping relationship with the wellbore casing 3975, a fluidicmaterial 3980 is preferably pumped into the chamber 3970. The fluidicmaterial 3980 then passes through the fluid passage 3920 into thechamber 3975. The fluidic material 3980 then passes out of the chamber3975, through the fluid passage 3945, and into the annular region 3970.In a preferred embodiment, the fluidic material 3980 is pumped into thechamber 3970 at operating pressures and flow rates ranging from about 0to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provideoperational efficiency. In a preferred embodiment, the fluidic material3980 comprises a hardenable fluidic sealing material in order to form ahardened outer annular member around the expanded tubular member 3925.

[0930] As illustrated in FIG. 24C, at some later point in the process, aball 3985, plug or other similar device, is introduced into the pumpedfluidic material 3980. In a preferred embodiment, the ball 3985 mateswith and seals off the inlet 3965 of the fluid passage 3920. In thismanner, the chamber 3970 is fluidicly isolated from the chamber 3975.

[0931] As illustrated in FIG. 24D, after placement of the ball 3985 inthe inlet 3965 of the fluid passage 3920, a fluidic material 3990 ispumped into the chamber 3970. The fluidic material is preferably pumpedinto the chamber 3970 at operating pressures and flow rates ranging fromabout 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to provideoptimal operating efficiency. The fluidic material 3990 may comprise anynumber of conventional commercially available materials such as, forexample, water, drilling mud, cement, epoxy, or slag mix. In a preferredembodiment, the fluidic material 3990 comprises a non-hardenable fluidicmaterial in order to maximize operational efficiency.

[0932] Continued pumping of the fluidic material 3990 increases fluidicmaterial 3980 increases the operating pressure within the chamber 3970.The increased operating pressure in the chamber 3970 then causes themandrel 3915 to extrude the mandrel launcher 3910 and tubular member3925 off of the conical face of the mandrel 3915. The extrusion of themandrel launcher 3910 and tubular member 3925 off of the conical face ofthe mandrel 3915 causes the mandrel launcher 3910 and tubular member3925 to expand in the radial direction. Continued pumping of the fluidicmaterial 3990 preferably causes the entire length of the tubular member3925 to expand in the radial direction.

[0933] In a preferred embodiment, the pumping rate and pressure of thefluidic material 3990 is reduced during the latter stages of theextrusion process in order to minimize shock to the apparatus 3900. In apreferred embodiment, the apparatus 3900 includes shock absorbers forabsorbing the shock caused by the completion of the extrusion process.In a preferred embodiment, the extrusion process causes the mandrel 3915to move in an axial direction 3995.

[0934] As illustrated in FIG. 24E, in a preferred embodiment, upon thecompletion of the extrusion process, the support member 3905, packer3910, first fluid conduit 3915, annular seal 3930, second fluid conduit3935, mandrel 3945, and mandrel launcher 3950 are removed from thewellbore 3980. In a preferred embodiment, the resulting new section ofwellbore casing includes the preexisting wellbore casing 3975, theexpanded tubular member 3925, the slips 3930, the seals 3935, the shoe3940, and an outer annular layer 4000 of hardened fluidic material.

[0935] In an alternative embodiment, the apparatus 3900 is used torepair a preexisting wellbore casing or pipeline. In this alternativeembodiment, both ends of the tubular member 3955 preferably includeslips 3960 and seals 3965.

[0936] In an alternative embodiment, the apparatus 3900 is used to forma tubular structural support for a building or offshore structure.

[0937] Referring to FIGS. 25 and 26, the optimal relationship betweenthe angle of attack of an expansion mandrel and the minimally requiredpropagation pressure during the expansion of a tubular member will nowbe described. As illustrated in FIG. 25, during the radial expansion ofa tubular member 4100 by an expansion mandrel 4105, the expansionmandrel 4105 is displaced in the axial direction. The angle of attack aof the conical surface 4110 of the expansion mandrel 4105 directlyaffects the required propagation pressure P_(PR) necessary to radiallyexpand the tubular member 4100. Referring to FIG. 26, for typical gradesof materials and typical geometries, the propagation pressure P_(PR) isminimized for an angle of attack of approximately 25 degrees.Furthermore, the optimal range of the angle of attack a ranges fromabout 10 to 30 degrees in order to minimize the range of requiredminimum propagation pressure P_(PR).

[0938] Referring to FIG. 27, an embodiment of an expandable threadedconnection 4300 will now be described. The expandable threadedconnection 4300 preferably includes a first tubular member 4305, asecond tubular member 4310, a threaded connection 4315, an O-ring groove4320, and an O-ring 4325.

[0939] The first tubular member 4305 includes an inside wall 4330 and anoutside wall 4335. The first tubular member 4305 preferably comprises anannular member having a substantially constant wall thickness. Thesecond tubular member 4310 includes an inside wall 4340 and an outsidewall 4345. The second tubular member 4310 preferably comprises anannular member having a substantially constant wall thickness.

[0940] The first and second tubular members, 4305 and 4310, may compriseany number of conventional commercially available members. In apreferred embodiment, the inside and outside diameters of the first andsecond tubular members, 4305 and 4310, are substantially equal. In thismanner, the burst strength of the tubular members, 4305 and 4310, aresubstantially equal. This minimizes the possibility of a catastrophicfailure during the radial expansion process.

[0941] The threaded connection 4315 may comprise any number ofconventional threaded connections suitable for use with tubular members.In a preferred embodiment, the threaded connection 4315 comprises apin-and-box threaded connection. In this manner, the assembly of thefirst tubular member 4305 to the second tubular member 4310 isoptimized.

[0942] The O-ring groove 4320 is preferably provided in the threadedportion of the interior wall 4340 of the second tubular member 4310. TheO-ring groove 4320 is preferably adapted to receive and support one ormore O-rings. The volumetric size of the O-ring groove 4320 ispreferably selected to permit the O-ring 4325 to expand at leastapproximately 20% in the axial direction during the radial expansionprocess. In this manner, deformation of the outer surface 4345 of thesecond tubular member 4310 during and upon the completion of the radialexpansion process is minimized.

[0943] The O-ring 4325 is supported by the O-ring groove 4320. TheO-ring 4325 optimally ensures that a fluid-tight seal is maintainedbetween the first tubular member 4305 and the second tubular member 4310throughout and upon the completion of the radial expansion process.

[0944] Referring to FIG. 28, an alternative embodiment of an expandablethreaded connection 4500 will now be described. The expandable threadedconnection 4500 includes a first tubular member 4505, a second tubularmember 4510, a threaded connection 4515, an O-ring groove 4520, and anO-ring 4525.

[0945] The first tubular member 4505 includes an inside wall 4530 and anoutside wall 4535. The first tubular member 4305 preferably comprises anannular member having a substantially constant wall thickness. Thesecond tubular member 4510 includes an inside wall 4540 and an outsidewall 4545. The second tubular member 4510 preferably comprises anannular member having a substantially constant wall thickness.

[0946] The first and second tubular members, 4505 and 4510, may compriseany number of conventional commercially available members. In apreferred embodiment, the inside and outside diameters of the first andsecond tubular members, 4505 and 4510, are substantially equal. In thismanner, the burst strength of the tubular members, 4505 and 4510, aresubstantially equal. This minimizes the possibility of a catastrophicfailure during the radial expansion process.

[0947] The threaded connection 4515 may comprise any number ofconventional threaded connections suitable for use with tubular members.In a preferred embodiment, the threaded connection 4515 comprises apin-and-box threaded connection. In this manner, the assembly of thefirst tubular member 4505 to the second tubular member 4510 isoptimized.

[0948] The O-ring groove 4520 is preferably provided in the threadedportion of the interior wall 4540 of the second tubular member 4510immediately adjacent to an end portion of the threaded connection 4515.In this manner, the sealing effect provided by the O-ring 4525 isoptimized. The O-ring groove 4520 is preferably adapted to receive andsupport one or more O-rings. The volumetric size of the O-ring groove4520 is preferably selected to permit the O-ring 4525 to expand at leastapproximately 20% in the axial direction during the radial expansionprocess. In this manner, deformation of the outer surface 4545 of thesecond tubular member 4510 during and upon the completion of the radialexpansion process is minimized.

[0949] The O-ring 4525 is supported by the O-ring groove 4520. TheO-ring 4525 optimally ensures that a fluid-tight seal is maintainedbetween the first tubular member 4505 and the second tubular member 4510throughout and upon the completion of the radial expansion process.

[0950] Referring to FIG. 29, an alternative embodiment of an expandablethreaded connection 4700 will now be described. The expandable threadedconnection 4700 includes a first tubular member 4705, a second tubularmember 4710, a threaded connection 4715, an O-ring groove 4720, a firstO-ring 4725, and a second O-ring 4730.

[0951] The first tubular member 4705 includes an inside wall 4735 and anoutside wall 4740. The first tubular member 4705 preferably comprises anannular member having a substantially constant wall thickness. Thesecond tubular member 4710 includes an inside wall 4745 and an outsidewall 4750. The second tubular member 4710 preferably comprises anannular member having a substantially constant wall thickness.

[0952] The first and second tubular members, 4705 and 4710, may compriseany number of conventional commercially available members. In apreferred embodiment, the inside and outside diameters of the first andsecond tubular members, 4705 and 4710, are substantially equal. In thismanner, the burst strength of the tubular members, 4705 and 4710, aresubstantially equal. This minimizes the possibility of a catastrophicfailure during the radial expansion process.

[0953] The threaded connection 4715 may comprise any number ofconventional threaded connections suitable for use with tubular members.In a preferred embodiment, the threaded connection 4715 comprises apin-and-box threaded connection. In this manner, the assembly of thefirst tubular member 4705 to the second tubular member 4710 isoptimized.

[0954] The O-ring groove 4720 is preferably provided in the threadedportion of the interior wall 4745 of the second tubular member 4710immediately adjacent to an end portion of the threaded connection 4715.In this manner, the sealing effect provided by the O-rings, 4725 and4730, is optimized. The O-ring groove 4720 is preferably adapted toreceive and support a plurality of O-rings. The volumetric size of theO-ring groove 4720 is preferably selected to permit the O-rings, 4725and 4730, to expand at least approximately 20% in the axial directionduring the radial expansion process. In this manner, deformation of theouter surface 4750 of the second tubular member 4710 during and upon thecompletion of the radial expansion process is minimized.

[0955] The O-rings, 4725 and 4730, are supported by the O-ring groove4720. The pair of O-rings, 4725 and 4730, optimally ensure that afluid-tight seal is maintained between the first tubular member 4705 andthe second tubular member 4710 throughout and upon the completion of theradial expansion process. In particular, the use of a pair of adjacentO-rings provides redundancy in the seal between the first tubular member4705 and the second tubular member 4710.

[0956] Referring to FIG. 30, an alternative embodiment of an expandablethreaded connection 4900 will now be described. The expandable threadedconnection 4900 includes a first tubular member 4905, a second tubularmember 4910, a threaded connection 4915, a first O-ring groove 4920, asecond O-ring grove 4925, a first O-ring 4930, and a second O-ring 4935.

[0957] The first tubular member 4905 includes an inside wall 4940 and anoutside wall 4945. The first tubular member 4905 preferably comprises anannular member having a substantially constant wall thickness. Thesecond tubular member 4910 includes an inside wall 4950 and an outsidewall 4955. The second tubular member 4910 preferably comprises anannular member having a substantially constant wall thickness.

[0958] The first and second tubular members, 4905 and 4910, may compriseany number of conventional commercially available tubular members. In apreferred embodiment, the inside and outside diameters of the first andsecond tubular members, 4905 and 4910, are substantially equal. In thismanner, the burst strength of the tubular members, 4905 and 4910, aresubstantially equal. This minimizes the possibility of a catastrophicfailure during the radial expansion process.

[0959] The threaded connection 4915 may comprise any number ofconventional threaded connections suitable for use with tubular members.In a preferred embodiment, the threaded connection 4915 comprises apin-and-box threaded connection. In this manner, the assembly of thefirst tubular member 4905 to the second tubular member 4910 isoptimized.

[0960] The first O-ring groove 4920 is preferably provided in thethreaded portion of the interior wall 4950 of the second tubular member4910 that is separated from an end portion of the threaded connection4915. In this manner, the sealing effect provided by the O-rings, 4930and 4935, is optimized. The first O-ring groove 4920 is preferablyadapted to receive and support one more O-rings. The volumetric size ofthe first O-ring groove 4920 is preferably selected to permit the O-ring4930 to expand at least approximately 20% in the axial direction duringthe radial expansion process. In this manner, deformation of the outersurface 4955 of the second tubular member 4910 during and upon thecompletion of the radial expansion process is minimized.

[0961] The second O-ring groove 4925 is preferably provided in thethreaded portion of the interior wall 4950 of the second tubular member4910 that is immediately adjacent to an end portion of the threadedconnection 4915. In this manner, the sealing effect provided by theO-rings, 4930 and 4935, is optimized. The second O-ring groove 4925 ispreferably adapted to receive and support one more O-rings. Thevolumetric size of the second O-ring groove 4925 is preferably selectedto permit the O-ring 4935 to expand at least approximately 20% in theaxial direction during the radial expansion process. In this manner,deformation of the outer surface 4955 of the second tubular member 4910during and upon the completion of the radial expansion process isminimized.

[0962] The O-rings, 4930 and 4935, are supported by the O-ring grooves,4920 and 4925. The use of a pair of O-rings, 4930 and 4935, that areaxially separated optimally ensures that a fluid-tight seal ismaintained between the first tubular member 4905 and the second tubularmember 4910 throughout and upon the completion of the radial expansionprocess. In particular, the use of a pair of O-rings provides redundancyin the seal between the first tubular member 4905 and the second tubularmember 4910.

[0963] In a preferred embodiment, the expandable threaded connections4300, 4500, 4700, and/or 4900 are used in combination with one or moreof the embodiments illustrated in FIGS. 1-24E in order to optimallyexpand a plurality of tubular members coupled end to end using theexpandable threaded connections 4300, 4500, 4700 and/or 4900.

[0964] Referring to FIG. 31, the lubrication of the interface between anexpansion mandrel and a tubular member during the radial expansionprocess will now be described. As illustrated in FIG. 31, during theradial expansion process, an expansion cone 5000 radially expands atubular member 5005 by moving in an axial direction 5010 relative to thetubular member 5005. The interface between the outer surface 5010 of thetapered portion 5015 of the expansion cone 5000 and the inner surface5020 of the tubular member 5005 includes a leading edge portion 5025 anda trailing edge portion 5030.

[0965] During the radial expansion process, the leading edge portion5025 is preferably lubricated by the presence of lubricating fluidsprovided ahead of the expansion cone 5000. However, because the radialclearance between the expansion cone 5000 and the tubular member 5005 inthe trailing edge portion 5030 during the radial expansion process istypically extremely small, and the operating contact pressures betweenthe tubular member 5005 and the expansion mandrel 5000 are extremelyhigh, the quantity of lubricating fluid provided to the trailing edgeportion 5030 is typically greatly reduced. In typical radial expansionoperations, this reduction in lubrication in the trailing edge portion5030 increases the forces required to radially expand the tubular member5005.

[0966] Referring to FIG. 32, an embodiment of a system for lubricatingthe interface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 32, anexpansion cone 5100, having a front end 5100 a and a rear end 5100 b,includes a tapered portion 5105 having an outer surface 3110, one ormore circumferential grooves 5115 a and 5115 b, and one more internalflow passages 5120 a and 5120 b.

[0967] In a preferred embodiment, the circumferential grooves 5115 arefluidicly coupled to the internal flow passages 5120. In this manner,during the radial expansion process, lubricating fluids are transmittedfrom the area ahead of the front 5100 a of the expansion cone 5100 intothe circumferential grooves 5115. Thus, the trailing edge portion of theinterface between the expansion cone 5100 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member. In apreferred embodiment, the lubricating fluids are injected into theinternal flow passages 5120 using a fluid conduit that is coupled to thetapered end 5105 of the expansion cone 5100. Alternatively, lubricatingfluids are provided for the internal flow passages 5120 using a supplyof lubricating fluids provided adjacent to the front 5100 a of theexpansion cone 5100.

[0968] In a preferred embodiment, the expansion cone 5100 includes aplurality of circumferential grooves 5115. In a preferred embodiment,the cross sectional area of the circumferential grooves 5115 range fromabout 2×10⁻⁴ in² to 5×10⁻² in² in order to optimally provide lubricationto the trailing edge portion of the interface between the expansion cone5100 and a tubular member during the radial expansion process. In apreferred embodiment, the expansion cone 5100 includes circumferentialgrooves 5115 concentrated about the axial midpoint of the taperedportion 5105 in order to optimally provide lubrication to the trailingedge portion of the interface between the expansion cone 5100 and atubular member during the radial expansion process. In a preferredembodiment, the circumferential grooves 5115 are equally spaced alongthe trailing edge portion of the expansion cone 5100 in order tooptimally provide lubrication to the trailing edge portion of theinterface between the expansion cone 5100 and a tubular member duringthe radial expansion process.

[0969] In a preferred embodiment, the expansion cone 5100 includes aplurality of flow passages 5120 coupled to each of the circumferentialgrooves 5115. In a preferred embodiment, the cross-sectional area of theflow passages 5120 ranges from about 2×10⁻⁴ in² to 5×10⁻² in² in orderto optimally provide lubrication to the trailing edge portion of theinterface between the expansion cone 5100 and a tubular member duringthe radial expansion process. In a preferred embodiment, the crosssectional area of the circumferential grooves 5115 is greater than thecross sectional area of the flow passage 5120 in order to minimizeresistance to fluid flow.

[0970] Referring to FIG. 33, another embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 33, an expansion cone 5200, having a front end 5200 a and a rearend 5200 b, includes a tapered portion 5205 having an outer surface5210, one or more circumferential grooves 5215 a and 5215 b, and one ormore axial grooves 5220 a and 5220 b.

[0971] In a preferred embodiment, the circumferential grooves 5215 arefluidicly coupled to the axial groves 5220. In this manner, during theradial expansion process, lubricating fluids are transmitted from thearea ahead of the front 5200 a of the expansion cone 5200 into thecircumferential grooves 5215. Thus, the trailing edge portion of theinterface between the expansion cone 5200 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member. In apreferred embodiment, the axial grooves 5220 are provided withlubricating fluid using a supply of lubricating fluid positionedproximate the front end 5200 a of the expansion cone 5200. In apreferred embodiment, the circumferential grooves 3215 are concentratedabout the axial midpoint of the tapered portion 5205 of the expansioncone 5200 in order to optimally provide lubrication to the trailing edgeportion of the interface between the expansion cone 5200 and a tubularmember during the radial expansion process. In a preferred embodiment,the circumferential grooves 5215 are equally spaced along the trailingedge portion of the expansion cone 5200 in order to optimally providelubrication to the trailing edge portion of the interface between theexpansion cone 5200 and a tubular member during the radial expansionprocess.

[0972] In a preferred embodiment, the expansion cone 5200 includes aplurality of circumferential grooves 5215. In a preferred embodiment,the cross sectional area of the circumferential grooves 5215 range fromabout 2×10⁻⁴ in² to 5×10⁻² in² in order to optimally provide lubricationto the trailing edge portion of the interface between the expansion cone5200 and a tubular member during the radial expansion process.

[0973] In a preferred embodiment, the expansion cone 5200 includes aplurality of axial grooves 5220 coupled to each of the circumferentialgrooves 5215. In a preferred embodiment, the cross sectional area of theaxial grooves 5220 ranges from about 2×10⁻⁴ in² to 5×10⁻² in² in orderto optimally provide lubrication to the trailing edge portion of theinterface between the expansion cone 5200 and a tubular member duringthe radial expansion process. In a preferred embodiment, the crosssectional area of the circumferential grooves 5215 is greater than thecross sectional area of the axial grooves 5220 in order to minimizeresistance to fluid flow. In a preferred embodiment, the axial groves5220 are spaced apart in the circumferential direction by at least about3 inches in order to optimally provide lubrication during the radialexpansion process.

[0974] Referring to FIG. 34, another embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 34, an expansion cone 5300, having a front end 5300 a and a rearend 5300 b, includes a tapered portion 5305 having an outer surface5310, one or more circumferential grooves 5315 a and 5315 b, and one ormore internal flow passages 5320 a and 5320 b.

[0975] In a preferred embodiment, the circumferential grooves 5315 arefluidicly coupled to the internal flow passages 5320. In this manner,during the radial expansion process, lubricating fluids are transmittedfrom the areas in front of the front 5300 a and/or behind the rear 5300b of the expansion cone 5300 into the circumferential grooves 5315.Thus, the trailing edge portion of the interface between the expansioncone 5300 and a tubular member is provided with an increased supply oflubricant, thereby reducing the amount of force required to radiallyexpand the tubular member. Furthermore, the lubricating fluids alsopreferably pass to the area in front of the expansion cone. In thismanner, the area adjacent to the front 5300 a of the expansion cone 5300is cleaned of foreign materials. In a preferred embodiment, thelubricating fluids are injected into the internal flow passages 5320 bypressurizing the area behind the rear 5300 b of the expansion cone 5300during the radial expansion process.

[0976] In a preferred embodiment, the expansion cone 5300 includes aplurality of circumferential grooves 5315. In a preferred embodiment,the cross sectional area of the circumferential grooves 5315 ranges fromabout 2×10⁻⁴ in² to 5×10⁻² in² respectively, in order to optimallyprovide lubrication to the trailing edge portion of the interfacebetween the expansion cone 5300 and a tubular member during the radialexpansion process. In a preferred embodiment, the expansion cone 5300includes circumferential grooves 5315 that are concentrated about theaxial midpoint of the tapered portion 5305 in order to optimally providelubrication to the trailing edge portion of the interface between theexpansion cone 5300 and a tubular member during the radial expansionprocess. In a preferred embodiment, the circumferential grooves 5315 areequally spaced along the trailing edge portion of the expansion cone5300 in order to optimally provide lubrication to the trailing edgeportion of the interface between the expansion cone 5300 and a tubularmember during the radial expansion process.

[0977] In a preferred embodiment, the expansion cone 5300 includes aplurality of flow passages 5320 coupled to each of the circumferentialgrooves 5315. In a preferred embodiment, the flow passages 5320fluidicly couple the front end 5300 a and the rear end 5300 b of theexpansion cone 5300. In a preferred embodiment, the cross-sectional areaof the flow passages 5320 ranges from about 2×10⁻⁴ in² to 5×10⁻² in² inorder to optimally provide lubrication to the trailing edge portion ofthe interface between the expansion cone 5300 and a tubular memberduring the radial expansion process. In a preferred embodiment, thecross sectional area of the circumferential grooves 5315 is greater thanthe cross-sectional area of the flow passages 5320 in order to minimizeresistance to fluid flow.

[0978] Referring to FIG. 35, an embodiment of a system for lubricatingthe interface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 35, anexpansion cone 5400, having a front end 5400 a and a rear end 5400 b,includes a tapered portion 5405 having an outer surface 5410, one ormore circumferential grooves 5415 a and 5415 b, and one or more axialgrooves 5420 a and 5420 b.

[0979] In a preferred embodiment, the circumferential grooves 5415 arefluidicly coupled to the axial grooves 5420. In this manner, during theradial expansion process, lubricating fluids are transmitted from theareas in front of the front 5400 a and/or behind the rear 5400 b of theexpansion cone 5400 into the circumferential grooves 5415. Thus, thetrailing edge portion of the interface between the expansion cone 5400and a tubular member is provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand thetubular member. Furthermore, in a preferred embodiment, pressurizedlubricating fluids pass from the fluid passages 5420 to the area infront of the front 5400 a of the expansion cone 5400. In this manner,the area adjacent to the front 5400 a of the expansion cone 5400 iscleaned of foreign materials. In a preferred embodiment, the lubricatingfluids are injected into the internal flow passages 5420 by pressurizingthe area behind the rear 5400 b expansion cone 5400 during the radialexpansion process.

[0980] In a preferred embodiment, the expansion cone 5400 includes aplurality of circumferential grooves 5415. In a preferred embodiment,the cross sectional area of the circumferential grooves 5415 range fromabout 2×10⁻⁴ in² to 5×10⁻² in² in order to optimally provide lubricationto the trailing edge portion of the interface between the expansion cone5400 and a tubular member during the radial expansion process. In apreferred embodiment, the expansion cone 5400 includes circumferentialgrooves 5415 that are concentrated about the axial midpoint of thetapered portion 5405 in order to optimally provide lubrication to thetrailing edge portion of the interface between the expansion cone 5400and a tubular member during the radial expansion process. In a preferredembodiment, the circumferential grooves 5415 are equally spaced alongthe trailing edge portion of the expansion cone 5400 in order tooptimally provide lubrication to the trailing edge portion of theinterface between the expansion cone 5400 and a tubular member duringthe radial expansion process.

[0981] In a preferred embodiment, the expansion cone 5400 includes aplurality of axial grooves 5420 coupled to each of the circumferentialgrooves 5415. In a preferred embodiment, the axial grooves 5420fluidicly couple the front end and the rear end of the expansion cone5400. In a preferred embodiment, the cross sectional area of the axialgrooves 5420 range from about 2×10⁻⁴ in² to 5×10⁻² in², respectively, inorder to optimally provide lubrication to the trailing edge portion ofthe interface between the expansion cone 5400 and a tubular memberduring the radial expansion process. In a preferred embodiment, thecross sectional area of the circumferential grooves 5415 is greater thanthe cross sectional area of the axial grooves 5420 in order to minimizeresistance to fluid flow. In a preferred embodiment, the axial grooves5420 are spaced apart in the circumferential direction by at least about3 inches in order to optimally provide lubrication during the radialexpansion process.

[0982] Referring to FIG. 36, another embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 36, an expansion cone 5500, having a front end 5500 a and a rearend 5500 b, includes a tapered portion 5505 having an outer surface5510, one or more circumferential grooves 5515 a and 5515 b, and one ormore axial grooves 5520 a and 5520 b.

[0983] In a preferred embodiment, the circumferential grooves 5515 arefluidicly coupled to the axial grooves 5520. In this manner, during theradial expansion process, lubricating fluids are transmitted from thearea ahead of the front 5500 a of the expansion cone 5500 into thecircumferential grooves 5515. Thus, the trailing edge portion of theinterface between the expansion cone 5500 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member. In apreferred embodiment, the lubricating fluids are injected into the axialgrooves 5520 using a fluid conduit that is coupled to the tapered end3205 of the expansion cone 3200.

[0984] In a preferred embodiment, the expansion cone 5500 includes aplurality of circumferential grooves 5515. In a preferred embodiment,the cross sectional area of the circumferential grooves 5515 ranges fromabout 2×10⁴ in² to 5×10⁻² in² in order to optimally provide lubricationto the trailing edge portion of the interface between the expansion cone5500 and a tubular member during the radial expansion process. In apreferred embodiment, the expansion cone 5500 includes circumferentialgrooves 5515 that are concentrated about the axial midpoint of thetapered portion 5505 in order to optimally provide lubrication to thetrailing edge portion of the interface between the expansion cone 5500and a tubular member during the radial expansion process. In a preferredembodiment, the circumferential grooves 5515 are equally spaced alongthe trailing edge portion of the expansion cone 5500 in order tooptimally provide lubrication to the trailing edge portion of theinterface between the expansion cone 5500 and a tubular member duringthe radial expansion process.

[0985] In a preferred embodiment, the expansion cone 5500 includes aplurality of axial grooves 5520 coupled to each of the circumferentialgrooves 5515. In a preferred embodiment, the axial grooves 5520intersect each of the circumferential groves 5515 at an acute angle. Ina preferred embodiment, the cross sectional area of the axial grooves5520 ranges from about 2×10⁻⁴ in² to 5×10⁻² in² in order to optimallyprovide lubrication to the trailing edge portion of the interfacebetween the expansion cone 5500 and a tubular member during the radialexpansion process. In a preferred embodiment, the cross sectional areaof the circumferential grooves 5515 is greater than the cross sectionalarea of the axial grooves 5520. In a preferred embodiment, the axialgrooves 5520 are spaced apart in the circumferential direction by atleast about 3 inches in order to optimally provide lubrication duringthe radial expansion process. In a preferred embodiment, the axialgrooves 5520 intersect the longitudinal axis of the expansion cone 5500at a larger angle than the angle of attack of the tapered portion 5505in order to optimally provide lubrication during the radial expansionprocess.

[0986] Referring to FIG. 37, another embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 37, an expansion cone 5600, having a front end 5600 a and a rearend 5600 b, includes a tapered portion 5605 having an outer surface5610, a spiral circumferential groove 5615, and one or more internalflow passages 5620.

[0987] In a preferred embodiment, the circumferential groove 5615 isfluidicly coupled to the internal flow passage 5620. In this manner,during the radial expansion process, lubricating fluids are transmittedfrom the area ahead of the front 5600 a of the expansion cone 5600 intothe circumferential groove 5615. Thus, the trailing edge portion of theinterface between the expansion cone 5600 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member. In apreferred embodiment, the lubricating fluids are injected into theinternal flow passage 5620 using a fluid conduit that is coupled to thetapered end 5605 of the expansion cone 5600.

[0988] In a preferred embodiment, the expansion cone 5600 includes aplurality of spiral circumferential grooves 5615. In a preferredembodiment, the cross sectional area of the circumferential groove 5615ranges from about 2×10⁴ in² to 5×10⁻² in² in order to optimally providelubrication to the trailing edge portion of the interface between theexpansion cone 5600 and a tubular member during the radial expansionprocess. In a preferred embodiment, the expansion cone 5600 includescircumferential grooves 5615 that are concentrated about the axialmidpoint of the tapered portion 5605 in order to optimally providelubrication to the trailing edge portion of the interface between theexpansion cone 5600 and a tubular member during the radial expansionprocess. In a preferred embodiment, the circumferential grooves 5615 areequally spaced along the trailing edge portion of the expansion cone5600 in order to optimally provide lubrication to the trailing edgeportion of the interface between the expansion cone 5600 and a tubularmember during the radial expansion process.

[0989] In a preferred embodiment, the expansion cone 5600 includes aplurality of flow passages 5620 coupled to each of the circumferentialgrooves 5615. In a preferred embodiment, the cross-sectional area of theflow passages 5620 ranges from about 2×10⁻⁴ in² to 5×10⁻² in² in orderto optimally provide lubrication to the trailing edge portion of theinterface between the expansion cone 5600 and a tubular member duringthe radial expansion process. In a preferred embodiment, the crosssectional area of the circumferential groove 5615 is greater than thecross sectional area of the flow passage 5620 in order to minimizeresistance to fluid flow.

[0990] Referring to FIG. 38, another embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 38, an expansion cone 5700, having a front end 5700 a and a rearend 5700 b, includes a tapered portion 5705 having an outer surface5710, a spiral circumferential groove 5715, and one or more axialgrooves 5720 a, 5720 b and 5720 c.

[0991] In a preferred embodiment, the circumferential groove 5715 isfluidicly coupled to the axial grooves 5720. In this manner, during theradial expansion process, lubricating fluids are transmitted from thearea ahead of the front 5700 a of the expansion cone 5700 into thecircumferential groove 5715. Thus, the trailing edge portion of theinterface between the expansion cone 5700 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member. In apreferred embodiment, the lubricating fluids are injected into the axialgrooves 5720 using a fluid conduit that is coupled to the tapered end5705 of the expansion cone 5700.

[0992] In a preferred embodiment, the expansion cone 5700 includes aplurality of spiral circumferential grooves 5715. In a preferredembodiment, the cross sectional area of the circumferential grooves 5715range from about 2×10⁻⁴ in² to 5×10⁻² in² in order to optimally providelubrication to the trailing edge portion of the interface between theexpansion cone 5700 and a tubular member during the radial expansionprocess. In a preferred embodiment, the expansion cone 5700 includescircumferential grooves 5715 concentrated about the axial midpoint ofthe tapered portion 5705 in order to optimally provide lubrication tothe trailing edge portion of the interface between the expansion cone5700 and a tubular member during the radial expansion process. In apreferred embodiment, the circumferential grooves 5715 are equallyspaced along the trailing edge portion of the expansion cone 5700 inorder to optimally provide lubrication to the trailing edge portion ofthe interface between the expansion cone 5700 and a tubular memberduring the radial expansion process.

[0993] In a preferred embodiment, the expansion cone 5700 includes aplurality of axial grooves 5720 coupled to each of the circumferentialgrooves 5715. In a preferred embodiment, the cross sectional area of theaxial grooves 5720 range from about 2×10⁻⁴ in² to 5×10⁻² in² in order tooptimally provide lubrication to the trailing edge portion of theinterface between the expansion cone 5700 and a tubular member duringthe radial expansion process. In a preferred embodiment, the axialgrooves 5720 intersect the circumferential grooves 5715 in aperpendicular manner. In a preferred embodiment, the cross sectionalarea of the circumferential groove 5715 is greater than the crosssectional area of the axial grooves 5720 in order to minimize resistanceto fluid flow. In a preferred embodiment, the circumferential spacing ofthe axial grooves is greater than about 3 inches in order to optimallyprovide lubrication during the radial expansion process. In a preferredembodiment, the axial grooves 5720 intersect the longitudinal axis ofthe expansion cone at an angle greater than the angle of attack of thetapered portion 5705 in order to optimally provide lubrication duringthe radial expansion process.

[0994] Referring to FIG. 39, a preferred embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 39, an expansion cone 5800, having a front end 5800 a and a rearend 5800 b, includes a tapered portion 5805 having an outer surface5810, a circumferential groove 5815, a first axial groove 5820, and oneor more second axial grooves 5825 a, 5825 b, 5825 c and 5825 d.

[0995] In a preferred embodiment, the circumferential groove 5815 isfluidicly coupled to the axial grooves 5820 and 5825. In this manner,during the radial expansion process, lubricating fluids are preferablytransmitted from the area behind the back 5800 b of the expansion cone5800 into the circumferential groove 5815. Thus, the trailing edgeportion of the interface between the expansion cone 5800 and a tubularmember is provided with an increased supply of lubricant, therebyreducing the amount of force required to radially expand the tubularmember. In a preferred embodiment, the lubricating fluids are injectedinto the first axial groove 5820 by pressurizing the region behind theback 5800 b of the expansion cone 5800. In a preferred embodiment, thelubricant is further transmitted into the second axial grooves 5825where the lubricant preferably cleans foreign materials from the taperedportion 5805 of the expansion cone 5800.

[0996] In a preferred embodiment, the expansion cone 5800 includes aplurality of circumferential grooves 5815. In a preferred embodiment,the cross sectional area of the circumferential groove 5815 ranges fromabout 2×10⁻⁴ in² to 5×10⁻² in² in order to optimally provide lubricationto the trailing edge portion of the interface between the expansion cone5800 and a tubular member during the radial expansion process. In apreferred embodiment, the expansion cone 5800 includes circumferentialgrooves 5815 concentrated about the axial midpoint of the taperedportion 5805 in order to optimally provide lubrication to the trailingedge portion of the interface between the expansion cone 5800 and atubular member during the radial expansion process. In a preferredembodiment, the circumferential grooves 5815 are equally spaced alongthe trailing edge portion of the expansion cone 5800 in order tooptimally provide lubrication to the trailing edge portion of theinterface between the expansion cone 5800 and a tubular member duringthe radial expansion process.

[0997] In a preferred embodiment, the expansion cone 5800 includes aplurality of first axial grooves 5820 coupled to each of thecircumferential grooves 5815. In a preferred embodiment, the first axialgrooves 5820 extend from the back 5800 b of the expansion cone 5800 andintersect the circumferential groove 5815. In a preferred embodiment,the cross sectional area of the first axial groove 5820 ranges fromabout 2×10⁻⁴ in² to 5×10⁻² in² in order to optimally provide lubricationto the trailing edge portion of the interface between the expansion cone5800 and a tubular member during the radial expansion process. In apreferred embodiment, the first axial groove 5820 intersects thecircumferential groove 5815 in a perpendicular manner. In a preferredembodiment, the cross sectional area of the circumferential groove 5815is greater than the cross sectional area of the first axial groove 5820in order to minimize resistance to fluid flow. In a preferredembodiment, the circumferential spacing of the first axial grooves 5820is greater than about 3 inches in order to optimally provide lubricationduring the radial expansion process.

[0998] In a preferred embodiment, the expansion cone 5800 includes aplurality of second axial grooves 5825 coupled to each of thecircumferential grooves 5815. In a preferred embodiment, the secondaxial grooves 5825 extend from the front 5800 a of the expansion cone5800 and intersect the circumferential groove 5815. In a preferredembodiment, the cross sectional area of the second axial grooves 5825ranges from about 2×10⁻⁴ in² to 5×10⁻² in² in order to optimally providelubrication to the trailing edge portion of the interface between theexpansion cone 5800 and a tubular member during the radial expansionprocess. In a preferred embodiment, the second axial grooves 5825intersect the circumferential groove 5815 in a perpendicular manner. Ina preferred embodiment, the cross sectional area of the circumferentialgroove 5815 is greater than the cross sectional area of the second axialgrooves 5825 in order to minimize resistance to fluid flow. In apreferred embodiment, the circumferential spacing of the second axialgrooves 5825 is greater than about 3 inches in order to optimallyprovide lubrication during the radial expansion process. In a preferredembodiment, the second axial grooves 5825 intersect the longitudinalaxis of the expansion cone 5800 at an angle greater than the angle ofattack of the tapered portion 5805 in order to optimally providelubrication during the radial expansion process.

[0999] Referring to FIG. 40, in a preferred embodiment, the first axialgroove 5820 includes a first portion 5905 having a first radius ofcurvature 5910, a second portion 5915 having a second radius ofcurvature 5920, and a third portion 5925 having a third radius ofcurvature 5930. In a preferred embodiment, the radius of curvatures,5910, 5920 and 5930 are substantially equal. In an exemplary embodiment,the radius of curvatures, 5910, 5920 and 5930 are all substantiallyequal to 0.0625 inches.

[1000] Referring to FIG. 41, in a preferred embodiment, thecircumferential groove 5815 includes a first portion 6005 having a firstradius of curvature 6010, a second portion 6015 having a second radiusof curvature 6020, and a third portion 6025 having a third radius ofcurvature 6030. In a preferred embodiment, the radius of curvatures,6010, 6020 and 6030 are substantially equal. In an exemplary embodiment,the radius of curvatures, 6010, 6020 and 6030 are all substantiallyequal to 0.125 inches.

[1001] Referring to FIG. 42, in a preferred embodiment, the second axialgroove 5825 includes a first portion 6105 having a first radius ofcurvature 6110, a second portion 6115 having a second radius ofcurvature 6120, and a third portion 6125 having a third radius ofcurvature 6130. In a preferred embodiment, the first radius of curvature6110 is greater than the third radius of curvature 6130. In an exemplaryembodiment, the first radius of curvature 6110 is equal to 0.5 inches,the second radius of curvature 6120 is equal to 0.0625 inches, and thethird radius of curvature 6130 is equal to 0.125 inches.

[1002] Referring to FIG. 43, an embodiment of an expansion mandrel 6200includes an internal flow passage 6205 having an insert 6210 including aflow passage 6215. In a preferred embodiment, the cross sectional areaof the flow passage 6215 is less than the cross sectional area of theflow passage 6215. More generally, in a preferred embodiment, aplurality of inserts 6210 are provided, each with different sizes offlow passages 6215. In this manner, the flow passage 6215 is machined toa standard size, and the lubricant supply is varied by using differentsized inserts 6210. In a preferred embodiment, the teachings of theexpansion mandrel 6200 are incorporated into the expansion mandrels5100, 5300, and 5600.

[1003] Referring to FIG. 44, in a preferred embodiment, the insert 6210includes a filter 6305 for filtering particles and other foreignmaterials from the lubricant that passes into the flow passage 6205. Inthis manner, the foreign materials are prevented from clogging the flowpassage 6205 and other flow passages within the expansion mandrel 6200.

[1004] In a preferred embodiment, the one or more of the lubricationsystems and elements of the mandrels 5100, 5200, 5300, 5400, 5500, 5600,5700, 5800 and/or 5900 are incorporated into the methods and apparatusfor expanding tubular members described above with reference to FIGS.1-30. In this manner, the amount of force required to radially expand atubular member in the formation and/or repair of a wellbore casing,pipeline, or structural support is significantly reduced. Furthermore,the increased lubrication provided to the trail edge portion of themandrel greatly reduces the amount of galling or seizure caused by theinterface between the mandrel and the tubular member during the radialexpansion process thereby permitting larger continuous sections oftubulars to be radially expanded in a single continuous operation. Thus,use of the mandrels 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800and/or 5900 reduces the operating pressures required for radialexpansion and thereby reduces the sizes of the required hydraulic pumpsand related equipment. In addition, failure, bursting, and/or bucklingof tubular members during the radial expansion process is significantlyreduced, and the success ratio of the radial expansion process isgreatly increased.

[1005] In laboratory tests, a regular expansion cone, without anylubrication grooves and flow passages, and the expansion cone 5100 wereboth used to radially expand identical coiled tubular members, eachhaving an outside diameter of 3½ inches. The following tables summarizesthe results of this laboratory test: REGULAR EXPANSION CONE EXPANSIONCONE 5100 LUBRICATING FLUID FORCE REQUIRED TO EXPAND TUBULAR MEMBER PHPAMud alone 78,000 Ibf 72,000 Ibf PHPA Mud + 7% Lubricant 48,000 Ibf46,000 lbf Blend 100% Lubricant Blend 68,000 Ibf 48,000 Ibf

[1006] Where:

[1007] PHPA Mud refers to a drilling mud mixture available from Baroid.

[1008] PHPA Mud+7% Lubricant Blend refers to a mixture of 93% PHPA Mudand 7% mixture of TorqTrim III, EP Mudlib, and DrillN-Slid availablefrom Baroid.

[1009] 100% Lubricant Blend refers to a mixture of TorqTrim III, EPMudlib, and DrillN-Slid available from Baroid.

[1010] Thus, in an exemplary embodiment, the use of the expansion cone5100 reduced the amount of force required to radially expand a tubularmember by as much as 30%. This reduction in the required forcetranslates to a corresponding reduction in the overall energyrequirements as well as a reduction in the size of required operatingequipment such as, for example, hydraulic pumping equipment. During thecourse of a typical expansion operation, this results in tremendous costsavings to the operator.

[1011] In a preferred embodiment, the lubricating fluids used with themandrels 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800 and 5900 forexpanding tubular members have viscosities ranging from about 1 to10,000 centipoise in order to optimize the injection of the lubricatingfluids into the circumferential grooves of the mandrels during theradial expansion process.

[1012] In a preferred embodiment, prior to placement in a wellbore, theouter surfaces of the apparatus for expanding tubular members describedabove with reference to FIGS. 1-30 are coated with a lubricating fluidto facilitate their placement the wellbore and reduce surge pressures.In a preferred embodiment, the lubricating fluid comprises BARO-LUBGOLD-SEAL™ brand drilling mud lubricant, available from Baroid DrillingFluids, Inc. In this manner, the insertion of the apparatus into awellbore, pipeline or other opening is optimized.

[1013] Referring to FIG. 45, a preferred embodiment of an expandibletubular 6400 for use in forming and/or repairing a wellbore casing,pipeline, or foundation support will now be described. In a preferredembodiment, the expandible tubular 6400 includes a wall thickness T.

[1014] In a preferred embodiment, the wall thickness T is substantiallyconstant throughout the expandible tubular 6400. In a preferredembodiment, the variation in the wall thickness T about thecircumference of the tubular member 6400 is less than about 8% in orderto optimally provide an expandible tubular 6400 having a substantiallyconstant hoop yield strength.

[1015] In a preferred embodiment, the material composition of and themanufacturing processes used in forming the expandible tubular 6400 areselected to provide a hoop yield strength that varies less than about10% about the circumference of the tubular member 6400 in order tooptimally provide consistent geometries in the expandible tubular 6400after radial expansion.

[1016] In a preferred embodiment, the expandible tubular 6400 includesstructural imperfections such as, for example, voids, foreign material,cracks, of less than about 5% of the specified wall thickness T in orderto optimize the radial expansion of the expandible tubular member 6400.In a preferred embodiment, each expandible tubular 6400 is tested forthe presence of such defects using nondestructive testing methods inaccordance with industry standard API SR2.

[1017] In a preferred embodiment, a representative sample of a selectedgroup of tubular members 6400 are flared at one end using a conventionalindustry standard tubular flaring method, such as, for example themethod disclosed in ASTM A450. As illustrated in FIG. 46, in a preferredembodiment, the walls of the flared end of the tubular member 6400 donot exhibit any necking for increases in the interior diameter of theflared end 6405 of the tubular member 6400 ranging from 0 to about 25%.As illustrated in FIG. 47, in a preferred embodiment, the flared end ofthe tubular member 6400 does not fail for increases in the interiordiameter of the flared end of the tubular members 6400 ranging from 0 toat least about 30%. In this manner, a selected group of tubular members6400 are optimally selected for both necking and ductility propertiessubsequent to radial expansion.

[1018] A method of creating a casing in a borehole located in asubterranean formation has been described that includes installing atubular liner and a mandrel in the borehole. A body of fluidic materialis then injected into the borehole. The tubular liner is then radiallyexpanded by extruding the liner off of the mandrel. The injectingpreferably includes injecting a hardenable fluidic sealing material intoan annular region located between the borehole and the exterior of thetubular liner; and a non hardenable fluidic material into an interiorregion of the tubular liner below the mandrel. The method preferablyincludes fluidicly isolating the annular region from the interior regionbefore injecting the second quantity of the non hardenable sealingmaterial into the interior region. The injecting the hardenable fluidicsealing material is preferably provided at operating pressures and flowrates ranging from about 0 to 5000 psi and 0 to 1,500 gallons/min. Theinjecting of the non hardenable fluidic material is preferably providedat operating pressures and flow rates ranging from about 500 to 9000 psiand 40 to 3,000 gallons/min. The injecting of the non hardenable fluidicmaterial is preferably provided at reduced operating pressures and flowrates during an end portion of the extruding. The non hardenable fluidicmaterial is preferably injected below the mandrel. The method preferablyincludes pressurizing a region of the tubular liner below the mandrel.The region of the tubular liner below the mandrel is preferablypressurized to pressures ranging from about 500 to 9,000 psi. The methodpreferably includes fluidicly isolating an interior region of thetubular liner from an exterior region of the tubular liner. The methodfurther preferably includes curing the hardenable sealing material, andremoving at least a portion of the cured sealing material located withinthe tubular liner. The method further preferably includes overlappingthe tubular liner with an existing wellbore casing. The method furtherpreferably includes sealing the overlap between the tubular liner andthe existing wellbore casing. The method further preferably includessupporting the extruded tubular liner using the overlap with theexisting wellbore casing. The method further preferably includes testingthe integrity of the seal in the overlap between the tubular liner andthe existing wellbore casing. The method further preferably includesremoving at least a portion of the hardenable fluidic sealing materialwithin the tubular liner before curing. The method further preferablyincludes lubricating the surface of the mandrel. The method furtherpreferably includes absorbing shock. The method further preferablyincludes catching the mandrel upon the completion of the extruding.

[1019] An apparatus for creating a casing in a borehole located in asubterranean formation has been described that includes a supportmember, a mandrel, a tubular member, and a shoe. The support memberincludes a first fluid passage. The mandrel is coupled to the supportmember and includes a second fluid passage. The tubular member iscoupled to the mandrel. The shoe is coupled to the tubular liner andincludes a third fluid passage. The first, second and third fluidpassages are operably coupled. The support member preferably furtherincludes a pressure relief passage, and a flow control valve coupled tothe first fluid passage and the pressure relief passage. The supportmember further preferably includes a shock absorber. The support memberpreferably includes one or more sealing members adapted to preventforeign material from entering an interior region of the tubular member.The mandrel is preferably expandable. The tubular member is preferablyfabricated from materials selected from the group consisting of OilfieldCountry Tubular Goods, 13 chromium steel tubing/casing, and plasticcasing. The tubular member preferably has inner and outer diametersranging from about 3 to 15.5 inches and 3.5 to 16 inches, respectively.The tubular member preferably has a plastic yield point ranging fromabout 40,000 to 135,000 psi. The tubular member preferably includes oneor more sealing members at an end portion. The tubular member preferablyincludes one or more pressure relief holes at an end portion. Thetubular member preferably includes a catching member at an end portionfor slowing down the mandrel. The shoe preferably includes an inlet portcoupled to the third fluid passage, the inlet port adapted to receive aplug for blocking the inlet port. The shoe preferably is drillable.

[1020] A method of joining a second tubular member to a first tubularmember, the first tubular member having an inner diameter greater thanan outer diameter of the second tubular member, has been described thatincludes positioning a mandrel within an interior region of the secondtubular member, positioning the first and second tubular members in anoverlapping relationship, pressurizing a portion of the interior regionof the second tubular member; and extruding the second tubular memberoff of the mandrel into engagement with the first tubular member. Thepressurizing of the portion of the interior region of the second tubularmember is preferably provided at operating pressures ranging from about500 to 9,000 psi. The pressurizing of the portion of the interior regionof the second tubular member is preferably provided at reduced operatingpressures during a latter portion of the extruding. The method furtherpreferably includes sealing the overlap between the first and secondtubular members. The method further preferably includes supporting theextruded first tubular member using the overlap with the second tubularmember. The method further preferably includes lubricating the surfaceof the mandrel. The method further preferably includes absorbing shock.

[1021] A liner for use in creating a new section of wellbore casing in asubterranean formation adjacent to an already existing section ofwellbore casing has been described that includes an annular member. Theannular member includes one or more sealing members at an end portion ofthe annular member, and one or more pressure relief passages at an endportion of the annular member.

[1022] A wellbore casing has been described that includes a tubularliner and an annular body of a cured fluidic sealing material. Thetubular liner is formed by the process of extruding the tubular lineroff of a mandrel. The tubular liner is preferably formed by the processof placing the tubular liner and mandrel within the wellbore, andpressurizing an interior portion of the tubular liner. The annular bodyof the cured fluidic sealing material is preferably formed by theprocess of injecting a body of hardenable fluidic sealing material intoan annular region external of the tubular liner. During thepressurizing, the interior portion of the tubular liner is preferablyfluidicly isolated from an exterior portion of the tubular liner. Theinterior portion of the tubular liner is preferably pressurized topressures ranging from about 500 to 9,000 psi. The tubular linerpreferably overlaps with an existing wellbore casing. The wellborecasing preferably further includes a seal positioned in the overlapbetween the tubular liner and the existing wellbore casing. Tubularliner is preferably supported the overlap with the existing wellborecasing.

[1023] A method of repairing an existing section of a wellbore casingwithin a borehole has been described that includes installing a tubularliner and a mandrel within the wellbore casing, injecting a body of afluidic material into the borehole, pressurizing a portion of aninterior region of the tubular liner, and radially expanding the linerin the borehole by extruding the liner off of the mandrel. In apreferred embodiment, the fluidic material is selected from the groupconsisting of slag mix, cement, drilling mud, and epoxy. In a preferredembodiment, the method further includes fluidicly isolating an interiorregion of the tubular liner from an exterior region of the tubularliner. In a preferred embodiment, the injecting of the body of fluidicmaterial is provided at operating pressures and flow rates ranging fromabout 500 to 9,000 psi and 40 to 3,000 gallons/min. In a preferredembodiment, the injecting of the body of fluidic material is provided atreduced operating pressures and flow rates during an end portion of theextruding. In a preferred embodiment, the fluidic material is injectedbelow the mandrel. In a preferred embodiment, a region of the tubularliner below the mandrel is pressurized. In a preferred embodiment, theregion of the tubular liner below the mandrel is pressurized topressures ranging from about 500 to 9,000 psi. In a preferredembodiment, the method further includes overlapping the tubular linerwith the existing wellbore casing. In a preferred embodiment, the methodfurther includes sealing the interface between the tubular liner and theexisting wellbore casing. In a preferred embodiment, the method furtherincludes supporting the extruded tubular liner using the existingwellbore casing. In a preferred embodiment, the method further includestesting the integrity of the seal in the interface between the tubularliner and the existing wellbore casing. In a preferred embodiment,method further includes lubricating the surface of the mandrel. In apreferred embodiment, the method further includes absorbing shock. In apreferred embodiment, the method further includes catching the mandrelupon the completion of the extruding. In a preferred embodiment, themethod further includes expanding the mandrel in a radial direction.

[1024] A tie-back liner for lining an existing wellbore casing has beendescribed that includes a tubular liner and an annular body of a curedfluidic sealing material. The tubular liner is formed by the process ofextruding the tubular liner off of a mandrel. The annular body of acured fluidic sealing material is coupled to the tubular liner. In apreferred embodiment, the tubular liner is formed by the process ofplacing the tubular liner and mandrel within the wellbore, andpressurizing an interior portion of the tubular liner. In a preferredembodiment, during the pressurizing, the interior portion of the tubularliner is fluidicly isolated from an exterior portion of the tubularliner. In a preferred embodiment, the interior portion of the tubularliner is pressurized at pressures ranging from about 500 to 9,000 psi.In a preferred embodiment, the annular body of a cured fluidic sealingmaterial is formed by the process of injecting a body of hardenablefluidic sealing material into an annular region between the existingwellbore casing and the tubular liner. In a preferred embodiment, thetubular liner overlaps with another existing wellbore casing. In apreferred embodiment, the tie-back liner further includes a sealpositioned in the overlap between the tubular liner and the otherexisting wellbore casing. In a preferred embodiment, tubular liner issupported by the overlap with the other existing wellbore casing.

[1025] An apparatus for expanding a tubular member has been describedthat includes a support member, a mandrel, a tubular member, and a shoe.The support member includes a first fluid passage. The mandrel iscoupled to the support member. The mandrel includes a second fluidpassage operably coupled to the first fluid passage, an interiorportion, and an exterior portion. The interior portion of the mandrel isdrillable. The tubular member is coupled to the mandrel. The shoe iscoupled to the tubular member. The shoe includes a third fluid passageoperably coupled to the second fluid passage, an interior portion, andan exterior portion. The interior portion of the shoe is drillable.Preferably, the interior portion of the mandrel includes a tubularmember and a load bearing member. Preferably, the load bearing membercomprises a drillable body. Preferably, the interior portion of the shoeincludes a tubular member, and a load bearing member. Preferably, theload bearing member comprises a drillable body. Preferably, the exteriorportion of the mandrel comprises an expansion cone. Preferably, theexpansion cone is fabricated from materials selected from the groupconsisting of tool steel, titanium, and ceramic. Preferably, theexpansion cone has a surface hardness ranging from about 58 to 62Rockwell C. Preferably at least a portion of the apparatus is drillable.

[1026] A wellhead has also been described that includes an outer casingand a plurality of substantially concentric and overlapping innercasings coupled to the outer casing. Each inner casing is supported bycontact pressure between an outer surface of the inner casing and aninner surface of the outer casing. In a preferred embodiment, the outercasing has a yield strength ranging from about 40,000 to 135,000 psi. Ina preferred embodiment, the outer casing has a burst strength rangingfrom about 5,000 to 20,000 psi. In a preferred embodiment, the contactpressure between the inner casings and the outer casing ranges fromabout 500 to 10,000 psi. In a preferred embodiment, one or more of theinner casings include one or more sealing members that contact with aninner surface of the outer casing. In a preferred embodiment, thesealing members are selected from the group consisting of lead, rubber,Teflon, epoxy, and plastic. In a preferred embodiment, a Christmas treeis coupled to the outer casing. In a preferred embodiment, a drillingspool is coupled to the outer casing. In a preferred embodiment, atleast one of the inner casings is a production casing.

[1027] A wellhead has also been described that includes an outer casingat least partially positioned within a wellbore and a plurality ofsubstantially concentric inner casings coupled to the interior surfaceof the outer casing by the process of expanding one or more of the innercasings into contact with at least a portion of the interior surface ofthe outer casing. In a preferred embodiment, the inner casings areexpanded by extruding the inner casings off of a mandrel. In a preferredembodiment, the inner casings are expanded by the process of placing theinner casing and a mandrel within the wellbore; and pressurizing aninterior portion of the inner casing. In a preferred embodiment, duringthe pressurizing, the interior portion of the inner casing is fluidiclyisolated from an exterior portion of the inner casing. In a preferredembodiment, the interior portion of the inner casing is pressurized atpressures ranging from about 500 to 9,000 psi. In a preferredembodiment, one or more seals are positioned in the interface betweenthe inner casings and the outer casing. In a preferred embodiment, theinner casings are supported by their contact with the outer casing.

[1028] A method of forming a wellhead has also been described thatincludes drilling a wellbore. An outer casing is positioned at leastpartially within an upper portion of the wellbore. A first tubularmember is positioned within the outer casing. At least a portion of thefirst tubular member is expanded into contact with an interior surfaceof the outer casing. A second tubular member is positioned within theouter casing and the first tubular member. At least a portion of thesecond tubular member is expanded into contact with an interior portionof the outer casing. In a preferred embodiment, at least a portion ofthe interior of the first tubular member is pressurized. In a preferredembodiment, at least a portion of the interior of the second tubularmember is pressurized. In a preferred embodiment, at least a portion ofthe interiors of the first and second tubular members are pressurized.In a preferred embodiment, the pressurizing of the portion of theinterior region of the first tubular member is provided at operatingpressures ranging from about 500 to 9,000 psi. In a preferredembodiment, the pressurizing of the portion of the interior region ofthe second tubular member is provided at operating pressures rangingfrom about 500 to 9,000 psi. In a preferred embodiment, the pressurizingof the portion of the interior region of the first and second tubularmembers is provided at operating pressures ranging from about 500 to9,000 psi. In a preferred embodiment, the pressurizing of the portion ofthe interior region of the first tubular member is provided at reducedoperating pressures during a latter portion of the expansion. In apreferred embodiment, the pressurizing of the portion of the interiorregion of the second tubular member is provided at reduced operatingpressures during a latter portion of the expansion. In a preferredembodiment, the pressurizing of the portion of the interior region ofthe first and second tubular members is provided at reduced operatingpressures during a latter portion of the expansions. In a preferredembodiment, the contact between the first tubular member and the outercasing is sealed. In a preferred embodiment, the contact between thesecond tubular member and the outer casing is sealed. In a preferredembodiment, the contact between the first and second tubular members andthe outer casing is sealed. In a preferred embodiment, the expandedfirst tubular member is supported using the contact with the outercasing. In a preferred embodiment, the expanded second tubular member issupported using the contact with the outer casing. In a preferredembodiment, the expanded first and second tubular members are supportedusing their contacts with the outer casing. In a preferred embodiment,the first and second tubular members are extruded off of a mandrel. In apreferred embodiment, the surface of the mandrel is lubricated. In apreferred embodiment, shock is absorbed. In a preferred embodiment, themandrel is expanded in a radial direction. In a preferred embodiment,the first and second tubular members are positioned in an overlappingrelationship. In a preferred embodiment, an interior region of the firsttubular member is fluidicly isolated from an exterior region of thefirst tubular member. In a preferred embodiment, an interior region ofthe second tubular member is fluidicly isolated from an exterior regionof the second tubular member. In a preferred embodiment, the interiorregion of the first tubular member is fluidicly isolated from the regionexterior to the first tubular member by injecting one or more plugs intothe interior of the first tubular member. In a preferred embodiment, theinterior region of the second tubular member is fluidicly isolated fromthe region exterior to the second tubular member by injecting one ormore plugs into the interior of the second tubular member. In apreferred embodiment, the pressurizing of the portion of the interiorregion of the first tubular member is provided by injecting a fluidicmaterial at operating pressures and flow rates ranging from about 500 to9,000 psi and 40 to 3,000 gallons/minute. In a preferred embodiment, thepressurizing of the portion of the interior region of the second tubularmember is provided by injecting a fluidic material at operatingpressures and flow rates ranging from about 500 to 9,000 psi and 40 to3,000 gallons/minute. In a preferred embodiment, fluidic material isinjected beyond the mandrel. In a preferred embodiment, a region of thetubular members beyond the mandrel is pressurized. In a preferredembodiment, the region of the tubular members beyond the mandrel ispressurized to pressures ranging from about 500 to 9,000 psi. In apreferred embodiment, the first tubular member comprises a productioncasing. In a preferred embodiment, the contact between the first tubularmember and the outer casing is sealed. In a preferred embodiment, thecontact between the second tubular member and the outer casing issealed. In a preferred embodiment, the expanded first tubular member issupported using the outer casing. In a preferred embodiment, theexpanded second tubular member is supported using the outer casing. In apreferred embodiment, the integrity of the seal in the contact betweenthe first tubular member and the outer casing is tested. In a preferredembodiment, the integrity of the seal in the contact between the secondtubular member and the outer casing is tested. In a preferredembodiment, the mandrel is caught upon the completion of the extruding.In a preferred embodiment, the mandrel is drilled out. In a preferredembodiment, the mandrel is supported with coiled tubing. In a preferredembodiment, the mandrel is coupled to a drillable shoe.

[1029] An apparatus has also been described that includes an outertubular member, and a plurality of substantially concentric andoverlapping inner tubular members coupled to the outer tubular member.Each inner tubular member is supported by contact pressure between anouter surface of the inner casing and an inner surface of the outerinner tubular member. In a preferred embodiment, the outer tubularmember has a yield strength ranging from about 40,000 to 135,000 psi. Ina preferred embodiment, the outer tubular member has a burst strengthranging from about 5,000 to 20,000 psi. In a preferred embodiment, thecontact pressure between the inner tubular members and the outer tubularmember ranges from about 500 to 10,000 psi. In a preferred embodiment,one or more of the inner tubular members include one or more sealingmembers that contact with an inner surface of the outer tubular member.In a preferred embodiment, the sealing members are selected from thegroup consisting of rubber, lead, plastic, and epoxy.

[1030] An apparatus has also been described that includes an outertubular member, and a plurality of substantially concentric innertubular members coupled to the interior surface of the outer tubularmember by the process of expanding one or more of the inner tubularmembers into contact with at least a portion of the interior surface ofthe outer tubular member. In a preferred embodiment, the inner tubularmembers are expanded by extruding the inner tubular members off of amandrel. In a preferred embodiment, the inner tubular members areexpanded by the process of: placing the inner tubular members and amandrel within the outer tubular member; and pressurizing an interiorportion of the inner casing. In a preferred embodiment, during thepressurizing, the interior portion of the inner tubular member isfluidicly isolated from an exterior portion of the inner tubular member.In a preferred embodiment, the interior portion of the inner tubularmember is pressurized at pressures ranging from about 500 to 9,000 psi.In a preferred embodiment, the apparatus further includes one or moreseals positioned in the interface between the inner tubular members andthe outer tubular member. In a preferred embodiment, the inner tubularmembers are supported by their contact with the outer tubular member.

[1031] A wellbore casing has also been described that includes a firsttubular member, and a second tubular member coupled to the first tubularmember in an overlapping relationship. The inner diameter of the firsttubular member is substantially equal to the inner diameter of thesecond tubular member. In a preferred embodiment, the first tubularmember includes a first thin wall section, wherein the second tubularmember includes a second thin wall section, and wherein the first thinwall section is coupled to the second thin wall section. In a preferredembodiment, first and second thin wall sections are deformed. In apreferred embodiment, the first tubular member includes a firstcompressible member coupled to the first thin wall section, and whereinthe second tubular member includes a second compressible member coupledto the second thin wall section. In a preferred embodiment, the firstthin wall section and the first compressible member are coupled to thesecond thin wall section and the second compressible member. In apreferred embodiment, the first and second thin wall sections and thefirst and second compressible members are deformed.

[1032] A wellbore casing has also been described that includes a tubularmember including at least one thin wall section and a thick wallsection, and a compressible annular member coupled to each thin wallsection. In a preferred embodiment, the compressible annular member isfabricated from materials selected from the group consisting of rubber,plastic, metal and epoxy. In a preferred embodiment, the wall thicknessof the thin wall section ranges from about 50 to 100% of the wallthickness of the thick wall section. In a preferred embodiment, thelength of the thin wall section ranges from about 120 to 2400 inches. Ina preferred embodiment, the compressible annular member is positionedalong the thin wall section. In a preferred embodiment, the compressibleannular member is positioned along the thin and thick wall sections. Ina preferred embodiment, the tubular member is fabricated from materialsselected from the group consisting of oilfield country tubular goods,stainless steel, low alloy steel, carbon steel, automotive grade steel,plastics, fiberglass, high strength and/or deformable materials. In apreferred embodiment, the wellbore casing includes a first thin wall ata first end of the casing, and a second thin wall at a second end of thecasing.

[1033] A method of creating a casing in a borehole located in asubterranean formation has also been described that includes supportinga tubular liner and a mandrel in the borehole using a support member,injecting fluidic material into the borehole, pressurizing an interiorregion of the mandrel, displacing a portion of the mandrel relative tothe support member, and radially expanding the tubular liner. In apreferred embodiment, the injecting includes injecting hardenablefluidic sealing material into an annular region located between theborehole and the exterior of the tubular liner, and injecting nonhardenable fluidic material into an interior region of the mandrel. In apreferred embodiment, the method further includes fluidicly isolatingthe annular region from the interior region before injecting the nonhardenable fluidic material into the interior region of the mandrel. Ina preferred embodiment, the injecting of the hardenable fluidic sealingmaterial is provided at operating pressures and flow rates ranging fromabout 0 to 5,000 psi and 0 to 1,500 gallons/min. In a preferredembodiment, the injecting of the non hardenable fluidic material isprovided at operating pressures and flow rates ranging from about 500 to9,000 psi and 40 to 3,000 gallons/min. In a preferred embodiment, theinjecting of the non hardenable fluidic material is provided at reducedoperating pressures and flow rates during an end portion of the radialexpansion. In a preferred embodiment, the fluidic material is injectedinto one or more pressure chambers. In a preferred embodiment, the oneor more pressure chambers are pressurized. In a preferred embodiment,the pressure chambers are pressurized to pressures ranging from about500 to 9,000 psi. In a preferred embodiment, the method further includesfluidicly isolating an interior region of the mandrel from an exteriorregion of the mandrel. In a preferred embodiment, the interior region ofthe mandrel is isolated from the region exterior to the mandrel byinserting one or more plugs into the injected fluidic material. In apreferred embodiment, the method further includes curing at least aportion of the fluidic material, and removing at least a portion of thecured fluidic material located within the tubular liner. In a preferredembodiment, the method further includes overlapping the tubular linerwith an existing wellbore casing. In a preferred embodiment, the methodfurther includes sealing the overlap between the tubular liner and theexisting wellbore casing. In a preferred embodiment, the method furtherincludes supporting the extruded tubular liner using the overlap withthe existing wellbore casing. In a preferred embodiment, the methodfurther includes testing the integrity of the seal in the overlapbetween the tubular liner and the existing wellbore casing. In apreferred embodiment, the method further includes removing at least aportion of the hardenable fluidic sealing material within the tubularliner before curing. In a preferred embodiment, the method furtherincludes lubricating the surface of the mandrel. In a preferredembodiment, the method further includes absorbing shock. In a preferredembodiment, the method further includes catching the mandrel upon thecompletion of the extruding. In a preferred embodiment, the methodfurther includes drilling out the mandrel. In a preferred embodiment,the method further includes supporting the mandrel with coiled tubing.In a preferred embodiment, the mandrel reciprocates. In a preferredembodiment, the mandrel is displaced in a first direction during thepressurization of the interior region of the mandrel, and the mandrel isdisplaced in a second direction during a de-pressurization of theinterior region of the mandrel. In a preferred embodiment, the tubularliner is maintained in a substantially stationary position during thepressurization of the interior region of the mandrel. In a preferredembodiment, the tubular liner is supported by the mandrel during ade-pressurization of the interior region of the mandrel.

[1034] A wellbore casing has also been described that includes a firsttubular member having a first inside diameter, and a second tubularmember having a second inside diameter substantially equal to the firstinside diameter coupled to the first tubular member in an overlappingrelationship. The first and second tubular members are coupled by theprocess of deforming a portion of the second tubular member into contactwith a portion of the first tubular member. In a preferred embodiment,the second tubular member is deformed by the process of placing thefirst and second tubular members in an overlapping relation ship,radially expanding at least a portion of the first tubular member, andradially expanding the second tubular member. In a preferred embodiment,the second tubular member is radially expanded by the process ofsupporting the second tubular member and a mandrel within the wellboreusing a support member, injecting a fluidic material into the wellbore,pressurizing an interior region of the mandrel, and displacing a portionof the mandrel relative to the support member. In a preferredembodiment, the injecting includes injecting hardenable fluidic sealingmaterial into an annular region located between the borehole and theexterior of the second liner, and injecting non hardenable fluidicmaterial into an interior region of the mandrel. In a preferredembodiment, the wellbore casing further includes fluidicly isolating theannular region from the interior region of the mandrel before injectingthe non hardenable fluidic material into the interior region of themandrel. In a preferred embodiment, the injecting of the hardenablefluidic sealing material is provided at operating pressures and flowrates ranging from about 0 to 5,000 psi and 0 to 1,500 gallons/min. In apreferred embodiment, the injecting of the non hardenable fluidicmaterial is provided at operating pressures and flow rates ranging fromabout 500 to 9,000 psi and 40 to 3,000 gallons/min. In a preferredembodiment, the injecting of the non hardenable fluidic material isprovided at reduced operating pressures and flow rates during an endportion of the radial expansion. In a preferred embodiment, the fluidicmaterial is injected into one or more pressure chambers. In a preferredembodiment, one or more pressure chambers are pressurized. In apreferred embodiment, the pressure chambers are pressurized to pressuresranging from about 500 to 9,000 psi. In a preferred embodiment, thewellbore casing further includes fluidicly isolating an interior regionof the mandrel from an exterior region of the mandrel. In a preferredembodiment, the interior region of the mandrel is isolated from theregion exterior to the mandrel by inserting one or more plugs into theinjected fluidic material. In a preferred embodiment, the wellborecasing further includes curing at least a portion of the fluidicmaterial, and removing at least a portion of the cured fluidic materiallocated within the second tubular liner. In a preferred embodiment, thewellbore casing further includes sealing the overlap between the firstand second tubular liners. In a preferred embodiment, the wellborecasing further includes supporting the second tubular liner using theoverlap with the first tubular liner. In a preferred embodiment, thewellbore casing further includes testing the integrity of the seal inthe overlap between the first and second tubular liners. In a preferredembodiment, the wellbore casing further includes removing at least aportion of the hardenable fluidic sealing material within the secondtubular liner before curing. In a preferred embodiment, the wellborecasing further includes lubricating the surface of the mandrel. In apreferred embodiment, the wellbore casing further includes absorbingshock. In a preferred embodiment, the wellbore casing further includescatching the mandrel upon the completion of the radial expansion. In apreferred embodiment, the wellbore casing further includes drilling outthe mandrel. In a preferred embodiment, the wellbore casing furtherinclude supporting the mandrel with coiled tubing. In a preferredembodiment, the mandrel reciprocates. In a preferred embodiment, themandrel is displaced in a first direction during the pressurization ofthe interior region of the mandrel; and wherein the mandrel is displacedin a second direction during a de-pressurization of the interior regionof the mandrel. In a preferred embodiment, the second tubular liner ismaintained in a substantially stationary position during thepressurization of the interior region of the mandrel. In a preferredembodiment, the second tubular liner is supported by the mandrel duringa de-pressurization of the interior region of the mandrel.

[1035] An apparatus for expanding a tubular member has also beendescribed that includes a support member including a fluid passage, amandrel movably coupled to the support member including an expansioncone, at least one pressure chamber defined by and positioned betweenthe support member and mandrel fluidicly coupled to the first fluidpassage, and one or more releasable supports coupled to the supportmember adapted to support the tubular member. In a preferred embodiment,the fluid passage includes a throat passage having a reduced innerdiameter. In a preferred embodiment, the mandrel includes one or moreannular pistons. In a preferred embodiment, the apparatus includes aplurality of pressure chambers. In a preferred embodiment, the pressurechambers are at least partially defined by annular pistons. In apreferred embodiment, the releasable supports are positioned below themandrel. In a preferred embodiment, the releasable supports arepositioned above the mandrel. In a preferred embodiment, the releasablesupports comprise hydraulic slips. In a preferred embodiment, thereleasable supports comprise mechanical slips. In a preferredembodiment, the releasable supports comprise drag blocks. In a preferredembodiment, the mandrel includes one or more annular pistons, and anexpansion cone coupled to the annular pistons. In a preferredembodiment, one or more of the annular pistons include an expansioncone. In a preferred embodiment, the pressure chambers comprise annularpressure chambers.

[1036] An apparatus has also been described that includes one or moresolid tubular members, each solid tubular member including one or moreexternal seals, one or more slotted tubular members coupled to the solidtubular members, and a shoe coupled to one of the slotted tubularmembers. In a preferred embodiment, the apparatus further includes oneor more intermediate solid tubular members coupled to and interleavedamong the slotted tubular members, each intermediate solid tubularmember including one or more external seals. In a preferred embodiment,the apparatus further includes one or more valve members. In a preferredembodiment, one or more of the intermediate solid tubular membersinclude one or more valve members.

[1037] A method of joining a second tubular member to a first tubularmember, the first tubular member having an inner diameter greater thanan outer diameter of the second tubular member, has also been describedthat includes positioning a mandrel within an interior region of thesecond tubular member, pressurizing a portion of the interior region ofthe mandrel, displacing the mandrel relative to the second tubularmember, and extruding at least a portion of the second tubular memberoff of the mandrel into engagement with the first tubular member. In apreferred embodiment, the pressurizing of the portion of the interiorregion of the mandrel is provided at operating pressures ranging fromabout 500 to 9,000 psi. In a preferred embodiment, the pressurizing ofthe portion of the interior region of the mandrel is provided at reducedoperating pressures during a latter portion of the extruding. In apreferred embodiment, the method further includes sealing the interfacebetween the first and second tubular members. In a preferred embodiment,the method further includes supporting the extruded second tubularmember using the interface with the first tubular member. In a preferredembodiment, the method further includes lubricating the surface of themandrel. In a preferred embodiment, the method further includesabsorbing shock. In a preferred embodiment, the method further includespositioning the first and second tubular members in an overlappingrelationship. In a preferred embodiment, the method further includesfluidicly isolating an interior region of the mandrel an exterior regionof the mandrel. In a preferred embodiment, the interior region of themandrel is fluidicly isolated from the region exterior to the mandrel byinjecting one or more plugs into the interior of the mandrel. In apreferred embodiment, the pressurizing of the portion of the interiorregion of the mandrel is provided by injecting a fluidic material atoperating pressures and flow rates ranging from about 500 to 9,000 psiand 40 to 3,000 gallons/minute. In a preferred embodiment, the methodfurther includes injecting fluidic material beyond the mandrel. In apreferred embodiment, one or more pressure chambers defined by themandrel are pressurized. In a preferred embodiment, the pressurechambers are pressurized to pressures ranging from about 500 to 9,000psi. In a preferred embodiment, the first tubular member comprises anexisting section of a wellbore. In a preferred embodiment, the methodfurther includes sealing the interface between the first and secondtubular members. In a preferred embodiment, the method further includessupporting the extruded second tubular member using the first tubularmember. In a preferred embodiment, the method further includes testingthe integrity of the seal in the interface between the first tubularmember and the second tubular member. In a preferred embodiment, themethod further includes catching the mandrel upon the completion of theextruding. In a preferred embodiment, the method further includesdrilling out the mandrel. In a preferred embodiment, the method furtherinclude supporting the mandrel with coiled tubing. In a preferredembodiment, the method further includes coupling the mandrel to adrillable shoe. In a preferred embodiment, the mandrel is displaced inthe longitudinal direction. In a preferred embodiment, the mandrel isdisplaced in a first direction during the pressurization and in a seconddirection during a de-pressurization.

[1038] An apparatus has also been described that includes one or moreprimary solid tubulars, each primary solid tubular including one or moreexternal annular seals, n slotted tubulars coupled to the primary solidtubulars, n−1 intermediate solid tubulars coupled to and interleavedamong the slotted tubulars, each intermediate solid tubular includingone or more external annular seals, and a shoe coupled to one of theslotted tubulars.

[1039] A method of isolating a first subterranean zone from a secondsubterranean zone in a wellbore has also been described that includespositioning one or more primary solid tubulars within the wellbore, theprimary solid tubulars traversing the first subterranean zone,positioning one or more slotted tubulars within the wellbore, theslotted tubulars traversing the second subterranean zone, fluidiclycoupling the slotted tubulars and the solid tubulars, and preventing thepassage of fluids from the first subterranean zone to the secondsubterranean zone within the wellbore external to the solid and slottedtubulars.

[1040] A method of extracting materials from a producing subterraneanzone in a wellbore, at least a portion of the wellbore including acasing, has also been described that includes positioning one or moreprimary solid tubulars within the wellbore, fluidicly coupling theprimary solid tubulars with the casing, positioning one or more slottedtubulars within the wellbore, the slotted tubulars traversing theproducing subterranean zone, fluidicly coupling the slotted tubularswith the solid tubulars, fluidicly isolating the producing subterraneanzone from at least one other subterranean zone within the wellbore, andfluidicly coupling at least one of the slotted tubulars from theproducing subterranean zone. In a preferred embodiment, the methodfurther includes controllably fluidicly decoupling at least one of theslotted tubulars from at least one other of the slotted tubulars.

[1041] A method of creating a casing in a borehole while also drillingthe borehole also has been described that includes installing a tubularliner, a mandrel, and a drilling assembly in the borehole. A fluidicmaterial is injected within the tubular liner, mandrel and drillingassembly. At least a portion of the tubular liner is radially expandedwhile the borehole is drilled using the drilling assembly. In apreferred embodiment, the injecting includes injecting the fluidicmaterial within an expandable chamber. In a preferred embodiment, theinjecting includes injecting hardenable fluidic sealing material into anannular region located between the borehole and the exterior of thetubular liner. In a preferred embodiment, the injecting of thehardenable fluidic sealing material is provided at operating pressuresand flow rates ranging from about 0 to 5,000 psi and 0 to 1,500gallons/min. In a preferred embodiment, the injecting of the fluidicmaterial is provided at operating pressures and flow rates ranging fromabout 500 to 9,000 psi and 40 to 3,000 gallons/min. In a preferredembodiment, the injecting of the fluidic material is provided at reducedoperating pressures and flow rates during an end portion of the radialexpansion. In a preferred embodiment, the method further includes curingat least a portion of the fluidic material; and removing at least aportion of the cured fluidic material located within the tubular liner.In a preferred embodiment, the method further includes overlapping thetubular liner with an existing wellbore casing. In a preferredembodiment, the method further includes sealing the overlap between thetubular liner and the existing wellbore casing. In a preferredembodiment, the method further includes supporting the extruded tubularliner using the overlap with the existing wellbore casing. In apreferred embodiment, the method further includes testing the integrityof the seal in the overlap between the tubular liner and the existingwellbore casing. In a preferred embodiment, the method further includeslubricating the surface of the mandrel. In a preferred embodiment, themethod further includes absorbing shock. In a preferred embodiment, themethod further includes catching the mandrel upon the completion of theextruding. In a preferred embodiment, the method further includesexpanding the mandrel in a radial direction. In a preferred embodiment,the method further includes drilling out the mandrel. In a preferredembodiment, the method further includes supporting the mandrel withcoiled tubing. In a preferred embodiment, the wall thickness of thetubular member is variable. In a preferred embodiment, the mandrel iscoupled to a drillable shoe.

[1042] An apparatus has also been described that includes a supportmember, the support member including a first fluid passage; a mandrelcoupled to the support member, the mandrel including: a second fluidpassage; a tubular member coupled to the mandrel; and a shoe coupled tothe tubular liner, the shoe including a third fluid passage; and adrilling assembly coupled to the shoe; wherein the first, second andthird fluid passages and the drilling assembly are operably coupled. Ina preferred embodiment, the support member further includes: a pressurerelief passage; and a flow control valve coupled to the first fluidpassage and the pressure relief passage. In a preferred embodiment, thesupport member further includes a shock absorber. In a preferredembodiment, the support member includes one or more sealing membersadapted to prevent foreign material from entering an interior region ofthe tubular member. In a preferred embodiment, the support memberincludes one or more stabilizers. In a preferred embodiment, the mandrelis expandable. In a preferred embodiment, the tubular member isfabricated from materials selected from the group consisting of OilfieldCountry Tubular Goods, automotive grade steel, plastic and chromiumsteel. In a preferred embodiment, the tubular member has inner and outerdiameters ranging from about 0.75 to 47 inches and 1.05 to 48 inches,respectively. In a preferred embodiment, the tubular member has aplastic yield point ranging from about 40,000 to 135,000 psi. In apreferred embodiment, the tubular member includes one or more sealingmembers at an end portion. In a preferred embodiment, the tubular memberincludes one or more pressure relief holes at an end portion. In apreferred embodiment, the tubular member includes a catching member atan end portion for slowing down movement of the mandrel. In a preferredembodiment, the support member comprises coiled tubing. In a preferredembodiment, at least a portion of the mandrel and shoe are drillable. Ina preferred embodiment, the wall thickness of the tubular member in anarea adjacent to the mandrel is less than the wall thickness of thetubular member in an area that is not adjacent to the mandrel. In apreferred embodiment, the apparatus further includes an expandablechamber. In a preferred embodiment, the expandable chamber isapproximately cylindrical. In a preferred embodiment, the expandablechamber is approximately annular.

[1043] A method of forming an underground pipeline within an undergroundtunnel including at least a first tubular member and a second tubularmember, the first tubular member having an inner diameter greater thanan outer diameter of the second tubular member, has also been describedthat includes positioning the first tubular member within the tunnel;positioning the second tubular member within the tunnel in anoverlapping relationship with the first tubular member; positioning amandrel and a drilling assembly within an interior region of the secondtubular member; injecting a fluidic material within the mandrel,drilling assembly and the second tubular member; extruding at least aportion of the second tubular member off of the mandrel into engagementwith the first tubular member; and drilling the tunnel. In a preferredembodiment, the injecting of the fluidic material is provided atoperating pressures ranging from about 500 to 9,000 psi. In a preferredembodiment, the injecting of the fluidic material is provided at reducedoperating pressures during a latter portion of the extruding. In apreferred embodiment, the method further includes sealing the interfacebetween the first and second tubular members. In a preferred embodiment,the method further includes supporting the extruded second tubularmember using the interface with the first tubular member. In a preferredembodiment, the method further includes lubricating the surface of themandrel. In a preferred embodiment, the method further includesabsorbing shock. In a preferred embodiment, the method further includesexpanding the mandrel in a radial direction. In a preferred embodiment,the method further includes testing the interface between the first andsecond tubular members. In a preferred embodiment, the method furtherincludes supporting the extruded second tubular member using the firsttubular member. In a preferred embodiment, the method further includestesting the integrity of the seal in the interface between the firsttubular member and the second tubular member. In a preferred embodiment,the method further includes catching the mandrel upon the completion ofthe extruding. In a preferred embodiment, the method further includesdrilling out the mandrel. In a preferred embodiment, the method furtherincludes supporting the mandrel with coiled tubing. In a preferredembodiment, the method further includes coupling the mandrel to adrillable shoe. In a preferred embodiment, the fluidic material isinjected into an expandable chamber. In a preferred embodiment, theexpandable chamber is substantially cylindrical. In a preferredembodiment, the expandable chamber is substantially annular.

[1044] An apparatus has also been described that includes a wellbore,the wellbore formed by the process of drilling the wellbore; and atubular liner positioned within the wellbore, the tubular liner formedby the process of extruding the tubular liner off of a mandrel whiledrilling the wellbore. In a preferred embodiment, the tubular liner isformed by the process of: placing the tubular liner and mandrel withinthe wellbore; and pressurizing an interior portion of the tubular liner.In a preferred embodiment, the interior portion of the tubular liner ispressurized at pressures ranging from about 500 to 9,000 psi. In apreferred embodiment, the tubular liner is formed by the process of:placing the tubular liner and mandrel within the wellbore; andpressurizing an interior portion of the mandrel. In a preferredembodiment, the interior portion of the mandrel is pressurized atpressures ranging from about 500 to 9,000 psi. In a preferredembodiment, the apparatus further includes an annular body of a curedfluidic material coupled to the tubular liner. In a preferredembodiment, the annular body of a cured fluidic sealing material isformed by the process of: injecting a body of hardenable fluidic sealingmaterial into an annular region external of the tubular liner. In apreferred embodiment, the tubular liner overlaps with an existingwellbore casing. In a preferred embodiment, the apparatus furtherincludes a seal positioned in the overlap between the tubular liner andthe existing wellbore casing. In a preferred embodiment, the tubularliner is supported by the overlap with the existing wellbore casing. Ina preferred embodiment, the process of extruding the tubular linerincludes the pressurizing of an expandable chamber. In a preferredembodiment, the expandable chamber is substantially cylindrical. In apreferred embodiment, the expandable chamber is substantially annular.

[1045] A method of forming a wellbore casing in a wellbore has also beendescribed that includes drilling out the wellbore while forming thewellbore casing. In a preferred embodiment, the forming includes:expanding a tubular member in the radial direction. In a preferredembodiment, the expanding includes: displacing a mandrel relative to thetubular member. In a preferred embodiment, the displacing includes:expanding an expandable chamber. In a preferred embodiment, theexpandable chamber comprises a cylindrical chamber. In a preferredembodiment, the expandable chamber comprises an annular chamber.

[1046] A method of expanding a tubular member has also been describedthat includes placing a mandrel within the tubular member, pressurizingan annular region within the tubular member, and displacing the mandrelwith respect to the tubular member. In a preferred embodiment, themethod further includes removing fluids within the tubular member thatare displaced by the displacement of the mandrel. In a preferredembodiment, the removed fluids pass inside the annular region. In apreferred embodiment, the volume of the annular region increases. In apreferred embodiment, the method further includes sealing off theannular region. In a preferred embodiment, sealing off the annularregion includes sealing a stationary member and sealing a non-stationarymember. In a preferred embodiment, the method further includes conveyingfluids in opposite directions. In a preferred embodiment, the methodfurther includes conveying a pressurized fluid and a non-pressurizedfluid in opposite directions. In a preferred embodiment, thepressurizing is provided at operating pressures ranging from about 0 to9,000 psi. In a preferred embodiment, the pressurizing is provided atflow rates ranging from about 0 to 3,000 gallons/minute.

[1047] A method of coupling a tubular member to preexisting structurehas also been described that includes positioning the tubular member inan overlapping relationship to the preexisting structure, placing amandrel within the tubular member, pressurizing an annular region withinthe tubular member, and displacing the mandrel with respect to thetubular member. In a preferred embodiment, the method further includesremoving fluids within the tubular member that are displaced by thedisplacement of the mandrel. In a preferred embodiment, the removedfluids pass inside the annular region. In a preferred embodiment, thevolume of the annular region increases. In a preferred embodiment, themethod further includes sealing off the annular region. In a preferredembodiment, sealing off the annular region includes sealing a stationarymember and sealing a non-stationary member. In a preferred embodiment,the method further includes conveying fluids in opposite directions. Ina preferred embodiment, the method further includes conveying apressurized fluid and a non-pressurized fluid in opposite directions. Ina preferred embodiment, the pressurizing is provided at operatingpressures ranging from about 0 to 9,000 psi. In a preferred embodiment,the pressurizing is provided at flow rates ranging from about 0 to 3,000gallons/minute.

[1048] A method of repairing a defect in a preexisting structure using atubular member has also been described that includes positioning thetubular member in an overlapping relationship to the defect in thepreexisting structure, placing a mandrel within the tubular member,pressurizing an annular region within the tubular member, and displacingthe mandrel with respect to the tubular member. In a preferredembodiment, the method further includes removing fluids within thetubular member that are displaced by the displacement of the mandrel. Ina preferred embodiment, the removed fluids pass inside the annularregion. In a preferred embodiment, the volume of the annular regionincreases. In a preferred embodiment, the method further includessealing off the annular region. In a preferred embodiment, sealing offthe annular region includes sealing a stationary member and sealing anon-stationary member. In a preferred embodiment, the method furtherincludes conveying fluids in opposite directions. In a preferredembodiment, the method further includes conveying a pressurized fluidand a non-pressurized fluid in opposite directions. In a preferredembodiment, the pressurizing is provided at operating pressures rangingfrom about 0 to 9,000 psi. In a preferred embodiment, the pressurizingis provided at flow rates ranging from about 0 to 3,000 gallons/minute.In a preferred embodiment, the method further includes sealing theinterface between the preexisting structure and the tubular member atends of the tubular member.

[1049] An apparatus for radially expanding a tubular member has alsobeen described that includes a first tubular member, a second tubularmember positioned within the first tubular member, a third tubularmember movably coupled to and positioned within the second tubularmember, a first annular sealing member for sealing an interface betweenthe first and second tubular members, a second annular sealing memberfor sealing an interface between the second and third tubular members,and a mandrel positioned within the first tubular member and coupled toan end of the third tubular member. In a preferred embodiment, theapparatus further includes an annular chamber defined by the firsttubular member, the second tubular member, the third tubular member, thefirst annular sealing member, the second annular sealing member, and themandrel. In a preferred embodiment, the apparatus further includes anannular passage defined by the second tubular member and the thirdtubular member. In a preferred embodiment, the apparatus furtherincludes a fluid passage contained within the third tubular member andthe mandrel. In a preferred embodiment, the apparatus further includesone or more sealing members coupled to an exterior surface of the firsttubular member. In a preferred embodiment, the apparatus furtherincludes an annular chamber defined by the first tubular member, thesecond tubular member, the third tubular member, the first annularsealing member, the second annular sealing member, and the mandrel, andannular passage defined by the second tubular member and the thirdtubular member. In a preferred embodiment, the annular chamber and theannular passage are fluidicly coupled. In a preferred embodiment, theapparatus further includes one or more slips coupled to the exteriorsurface of the first tubular member. In a preferred embodiment, themandrel includes a conical surface. In a preferred embodiment, the angleof attack of the conical surface ranges from about 10 to 30 degrees. Ina preferred embodiment, the conical surface has a surface hardnessranging from about 58 to 62 Rockwell C.

[1050] An apparatus has also been described that includes a tubularmember, a piston adapted to expand the diameter of the tubular memberpositioned within the tubular member, the piston including a passage forconveying fluids out of the tubular member, and an annular chamberdefined by the piston and tubular member. In a preferred embodiment, thepiston includes a conical surface. In a preferred embodiment, the angleof attack of the conical surface ranges from about 10 to 30 degrees. Ina preferred embodiment, the conical surface has a surface hardnessranging from about 58 to 62 Rockwell C. In a preferred embodiment, thetubular member includes one or more sealing members coupled to theexterior surface of the tubular member.

[1051] A wellbore casing has also been described that includes a firsttubular member and a second tubular member coupled to the first tubularmember. The second tubular member is coupled to the first tubular memberby the process of positioning the second tubular member in anoverlapping relationship to the first tubular member, placing a mandrelwithin the second tubular member, pressurizing an annular region withinthe second tubular member, and displacing the mandrel with respect tothe second tubular member. In a preferred embodiment, the wellborecasing further includes removing fluids within the second tubular memberthat are displaced by the displacement of the mandrel. In a preferredembodiment, the removed fluids pass inside the annular region. In apreferred embodiment, the volume of the annular region increases. In apreferred embodiment, the wellbore casing further includes sealing offthe annular region. In a preferred embodiment, sealing off the annularregion includes sealing a stationary member and sealing a non-stationarymember. In a preferred embodiment, the wellbore casing further includingconveying fluids in opposite directions. In a preferred embodiment, thewellbore casing further includes conveying a pressurized fluid and anon-pressurized fluid in opposite directions. In a preferred embodiment,the pressurizing is provided at operating pressures ranging from about 0to 9,000 psi. In a preferred embodiment, the pressurizing is provided atflow rates ranging from about 0 to 3,000 gallons/minute.

[1052] An apparatus has also been described that includes a preexistingstructure and a tubular member coupled to the preexisting structure. Thetubular member is coupled to the preexisting structure by the processof: positioning the tubular member in an overlapping relationship to thepreexisting structure, placing a mandrel within the tubular member,pressurizing an annular region within the tubular member, and displacingthe mandrel with respect to the tubular member. In a preferredembodiment, the apparatus further includes removing fluids within thetubular member that are displaced by the displacement of the mandrel. Ina preferred embodiment, the removed fluids pass inside the annularregion. In a preferred embodiment, the volume of the annular regionincreases. In a preferred embodiment, the apparatus further includessealing off the annular region. In a preferred embodiment, sealing offthe annular region includes sealing a stationary member and sealing anon-stationary member. In a preferred embodiment, the apparatus furtherincludes conveying fluids in opposite directions. In a preferredembodiment, the apparatus further includes conveying a pressurized fluidand a non-pressurized fluid in opposite directions. In a preferredembodiment, the pressurizing is provided at operating pressures rangingfrom about 0 to 9,000 psi. In a preferred embodiment, the pressurizingis provided at flow rates ranging from about 0 to 3,000 gallons/minute.

[1053] An apparatus has also been described that includes a preexistingstructure having a defective portion and a tubular member coupled to thedefective portion of the preexisting structure. The tubular member iscoupled to the defective portion of the preexisting structure by theprocess of: positioning the tubular member in an overlappingrelationship to the defect in the preexisting structure, placing amandrel within the tubular member, pressurizing an annular region withinthe tubular member, and displacing the mandrel with respect to thetubular member. In a preferred embodiment, the apparatus furtherincludes removing fluids within the tubular member that are displaced bythe displacement of the mandrel. In a preferred embodiment, the removedfluids pass inside the annular region. In a preferred embodiment, thevolume of the annular region increases. In a preferred embodiment, theapparatus further includes sealing off the annular region. In apreferred embodiment, sealing off the annular region includes sealing astationary member and sealing a non-stationary member. In a preferredembodiment, the apparatus further includes conveying fluids in oppositedirections. In a preferred embodiment, the apparatus further includesconveying a pressurized fluid and a non-pressurized fluid in oppositedirections. In a preferred embodiment, the pressurizing is provided atoperating pressures ranging from about 0 to 9,000 psi. In a preferredembodiment, the pressurizing is provided at flow rates ranging fromabout 0 to 3,000 gallons/minute. In a preferred embodiment, theapparatus further includes sealing the interface between the preexistingstructure and the tubular member at ends of the tubular member.

[1054] A method of expanding a tubular member has also been describedthat includes placing a mandrel within the tubular member, pressurizinga region within the tubular member, and displacing the mandrel withrespect to the tubular member. In a preferred embodiment, thepressurizing is provided at operating pressures ranging from about 0 to9,000 psi. In a preferred embodiment, the pressurizing is provided atflow rates ranging from about 0 to 3,000 gallons/minute. In a preferredembodiment, the tubular member is expanded beginning at an upper portionof the tubular member.

[1055] A method of coupling a tubular member to preexisting structurehas also been described that includes positioning the tubular member inan overlapping relationship to the preexisting structure, placing amandrel within the tubular member, pressurizing an interior regionwithin the tubular member, and displacing the mandrel with respect tothe tubular member. In a preferred embodiment, the pressurizing isprovided at operating pressures ranging from about 0 to 9,000 psi. In apreferred embodiment, the pressurizing is provided at flow rates rangingfrom about 0 to 3,000 gallons/minute. In a preferred embodiment, thetubular member is expanded beginning at an upper portion of the tubularmember.

[1056] A method of repairing a defect in a preexisting structure using atubular member has also been described that includes positioning thetubular member in an overlapping relationship to the defect in thepreexisting structure, placing a mandrel within the tubular member,pressurizing an interior region within the tubular member, anddisplacing the mandrel with respect to the tubular member. In apreferred embodiment, the pressurizing is provided at operatingpressures ranging from about 0 to 9,000 psi. In a preferred embodiment,the pressurizing is provided at flow rates ranging from about 0 to 3,000gallons/minute. In a preferred embodiment, the tubular member isexpanded beginning at an upper portion of the tubular member. In apreferred embodiment, the method further includes sealing the interfacebetween the preexisting structure and the tubular member at both ends ofthe tubular member.

[1057] An apparatus for radially expanding a tubular member has alsobeen described that includes a first tubular member, a second tubularmember coupled to the first tubular member, a third tubular membercoupled to the second tubular member, and a mandrel positioned withinthe second tubular member and coupled to an end portion of the thirdtubular member. In a preferred embodiment, the mandrel includes a fluidpassage having an inlet adapted to receive fluid stop member. In apreferred embodiment, the apparatus further includes one or more slipscoupled to the exterior surface of the third tubular member. In apreferred embodiment, the mandrel includes a conical surface. In apreferred embodiment, the angle of attack of the conical surface rangesfrom about 10 to 30 degrees. In a preferred embodiment, the conicalsurface has a surface hardness ranging from about 58 to 62 Rockwell C.In a preferred embodiment, the average inside diameter of the secondtubular member is greater than the average inside diameter of the thirdtubular member.

[1058] An apparatus has also been described that includes a tubularmember, a piston adapted to expand the diameter of the tubular memberpositioned within the tubular member, the piston including a passage forconveying fluids out of the tubular member. In a preferred embodiment,the piston includes a conical surface. In a preferred embodiment, theangle of attack of the conical surface ranges from about 10 to 30degrees. In a preferred embodiment, the conical surface has a surfacehardness ranging from about 58 to 62 Rockwell C. In a preferredembodiment, the tubular member includes one or more sealing memberscoupled to the exterior surface of the tubular member.

[1059] A wellbore casing has also been described that includes a firsttubular member and a second tubular member coupled to the first tubularmember. The second tubular member is coupled to the first tubular memberby the process of: positioning the second tubular member in anoverlapping relationship to the first tubular member, placing a mandrelwithin the second tubular member, pressurizing an interior region withinthe second tubular member, and displacing the mandrel with respect tothe second tubular member. In a preferred embodiment, the pressurizingis provided at operating pressures ranging from about 0 to 9,000 psi. Ina preferred embodiment, the pressurizing is provided at flow ratesranging from about 0 to 3,000 gallons/minute.

[1060] An apparatus has also been described that includes a preexistingstructure and a tubular member coupled to the preexisting structure. Thetubular member is coupled to the preexisting structure by the processof: positioning the tubular member in an overlapping relationship to thepreexisting structure, placing a mandrel within the tubular member,pressurizing an interior region within the tubular member, anddisplacing the mandrel with respect to the tubular member. In apreferred embodiment, the pressurizing is provided at operatingpressures ranging from about 0 to 9,000 psi. In a preferred embodiment,the pressurizing is provided at flow rates ranging from about 0 to 3,000gallons/minute.

[1061] An apparatus has also been described that includes a preexistingstructure having a defective portion and a tubular member coupled to thedefective portion of the preexisting structure. The tubular member iscoupled to the defective portion of the preexisting structure by theprocess of: positioning the tubular member in an overlappingrelationship to the defect in the preexisting structure, placing amandrel within the tubular member, pressurizing an interior regionwithin the tubular member, and displacing the mandrel with respect tothe tubular member. In a preferred embodiment, the pressurizing isprovided at operating pressures ranging from about 0 to 9,000 psi. In apreferred embodiment, the pressurizing is provided at flow rates rangingfrom about 0 to 3,000 gallons/minute. In a preferred embodiment, theapparatus further includes sealing the interface between the preexistingstructure and the tubular member at both ends of the tubular member.

[1062] An apparatus also has been described that includes a firsttubular member, a second tubular member, and a threaded connection forcoupling the first tubular member to the second tubular member. Thethreaded connection includes one or more sealing members for sealing theinterface between the first and second tubular members. In a preferredembodiment, the threaded connection comprises a pin and box threadedconnection. In a preferred embodiment, the sealing members arepositioned adjacent to an end portion of the threaded connection. In apreferred embodiment, one of the sealing members is positioned adjacentto an end portion of the threaded connection; and wherein another one ofthe sealing members is not positioned adjacent to an end portion of thethreaded connection. In a preferred embodiment, a plurality of thesealing members are positioned adjacent to an end portion of thethreaded connection.

[1063] An apparatus also has been described that includes a tubularassembly having a first tubular member, a second tubular member, and athreaded connection for coupling the first tubular member to the secondtubular member. The threaded connection includes one or more sealingmembers for sealing the interface between the first and second tubularmembers. The tubular assembly is formed by the process of radiallyexpanding the tubular assembly. In a preferred embodiment, the threadedconnection comprises a pin and box threaded connection. In a preferredembodiment, the sealing members are positioned adjacent to an endportion of the threaded connection. In a preferred embodiment, one ofthe sealing members is positioned adjacent to an end portion of thethreaded connection; and wherein another one of the sealing members isnot positioned adjacent to an end portion of the threaded connection. Ina preferred embodiment, a plurality of the sealing members arepositioned adjacent to an end portion of the threaded connection.

[1064] An apparatus also has been described that includes a tubularmember and a mandrel positioned within the tubular member including aconical surface have an angle of attack ranging from about 10 to 30degrees. In a preferred embodiment, the tubular member includes a firsttubular member, a second tubular member, and a threaded connection forcoupling the first tubular member to the second tubular member. Thethreaded connection includes one or more sealing members for sealing theinterface between the first and second tubular members. In a preferredembodiment, the threaded connection comprises a pin and box threadedconnection. In a preferred embodiment, the sealing members arepositioned adjacent to an end portion of the threaded connection. In apreferred embodiment, one of the sealing members is positioned adjacentto an end portion of the threaded connection; and wherein another one ofthe sealing members is not positioned adjacent to an end portion of thethreaded connection. In a preferred embodiment, a plurality of thesealing members are positioned adjacent to an end portion of thethreaded connection.

[1065] An expansion cone for expanding a tubular member has also beendescribed that includes a housing including a tapered first end and asecond end, one or more grooves formed in the outer surface of thetapered first end, and one or more axial flow passages fluidicly coupledto the circumferential grooves. In a preferred embodiment, the groovescomprise circumferential grooves. In a preferred embodiment, the groovescomprise spiral grooves. In a preferred embodiment, the grooves areconcentrated around the axial midpoint of the tapered portion of thehousing. In a preferred embodiment, the axial flow passages compriseaxial grooves. In a preferred embodiment, the axial grooves are spacedapart by at least about 3 inches in the circumferential direction. In apreferred embodiment, the axial grooves extend from the tapered firstend of the body to the grooves. In a preferred embodiment, the axialgrooves extend from the second end of the body to the grooves. In apreferred embodiment, the axial grooves extend from the tapered firstend of the body to the second end of the body. In a preferredembodiment, the flow passages are positioned within the housing of theexpansion cone. In a preferred embodiment, the flow passages extend fromthe tapered first end of the body to the grooves. In a preferredembodiment, the flow passages extend from the tapered first end of thebody to the second end of the body. In a preferred embodiment, the flowpassages extend from the second end of the body to the grooves. In apreferred embodiment, one or more of the flow passages include insertshaving restricted flow passages. In a preferred embodiment, one or moreof the flow passages include filters. In a preferred embodiment, thecross sectional area of the grooves is greater than the cross sectionalarea of the axial flow passages. In a preferred embodiment, thecross-sectional area of the grooves ranges from about 2×10⁻⁴ in² to5×10⁻² in². In a preferred embodiment, the cross-sectional area of theaxial flow passages ranges from about 2×10⁻⁴ in² to 5×10⁻² in². In apreferred embodiment, the angle of attack of the first tapered end ofthe body ranges from about 10 to 30 degrees. In a preferred embodiment,the grooves are concentrated in a trailing edge portion of the taperedfirst end. In a preferred embodiment, the angle of inclination of theaxial flow passages relative to the longitudinal axis of the expansioncone is greater than the angle of attack of the first tapered end. In apreferred embodiment, the grooves include a flow channel having a firstradius of curvature, a first shoulder positioned on one side of the flowchannel having a second radius of curvature, and a second shoulderpositioned on the other side of the flow channel having a third radiusof curvature. In a preferred embodiment, the first, second and thirdradii of curvature are substantially equal. In a preferred embodiment,the the axial flow passages include a flow channel having a first radiusof curvature, a first shoulder positioned on one side of the flowchannel having a second radius of curvature, and a second shoulderpositioned on the other side of the flow channel having a third radiusof curvature. In a preferred embodiment, the first, second and thirdradii of curvature are substantially equal. In a preferred embodiment,the second radius of curvature is greater than the third radius ofcurvature.

[1066] A method of lubricating the interface between a tubular memberand an expansion cone having a first tapered end and a second end duringthe radial expansion of the tubular member by the expansion cone,wherein the interface between the tubular member and the first taperedend of the expansion cone includes a leading edge portion and a trailingedge portion, has also been described that includes injecting alubricating fluid into the trailing edge portion. In a preferredembodiment, the lubricating fluid has a viscosity ranging from about 1to 10,000 centipoise. In a preferred embodiment, the injecting includesinjecting lubricating fluid into the first tapered end of the expansioncone. In a preferred embodiment, the injecting includes injectinglubricating fluid into the area around the axial midpoint of the firsttapered end of the expansion cone. In a preferred embodiment, theinjecting includes injecting lubricating fluid into the second end ofthe expansion cone. In a preferred embodiment, the injecting includesinjecting lubricating fluid into the tapered first end and the secondend of the expansion cone. In a preferred embodiment, the injectingincludes injecting lubricating fluid into the interior of the expansioncone. In a preferred embodiment, the injecting includes injectinglubricating fluid through the outer surface of the expansion cone. In apreferred embodiment, the injecting includes injecting the lubricatingfluid into a plurality of discrete locations along the trailing edgeportion. In a preferred embodiment, the lubricating fluid comprisesdrilling mud. In a preferred embodiment, the lubricating fluid furtherincludes TorqTrim III, EP Mudlib, and DrillN-Slid. In a preferredembodiment, the lubricating fluid comprises TorqTrim III, EP Mudlib, andDrillN-Slid.

[1067] A method of removing debris formed during the radial expansion ofa tubular member by an expansion cone from the interface between thetubular member and the expansion cone, the expansion cone including afirst tapered end and a second end, the interface between the tubularmember and the first tapered end of the expansion cone includes aleading edge portion and a trailing edge portion, also has beendescribed that includes injecting a lubricating fluid into the interfacebetween the tubular member and the expansion cone. In a preferredembodiment, the lubricating fluid has a viscosity ranging from about 1to 10,000 centipoise. In a preferred embodiment, the injecting includesinjecting lubricating fluid into the first tapered end of the expansioncone. In a preferred embodiment, the injecting includes injectinglubricating fluid into the area around the axial midpoint of the firsttapered end of the expansion cone. In a preferred embodiment, theinjecting includes injecting lubricating fluid into the second end ofthe expansion cone. In a preferred embodiment, the injecting includesinjecting lubricating fluid into the tapered first end and the secondend of the expansion cone. In a preferred embodiment, the injectingincludes injecting lubricating fluid into the interior of the expansioncone. In a preferred embodiment, the injecting includes injectinglubricating fluid through the outer surface of the expansion cone. In apreferred embodiment, the lubricating fluid comprises drilling mud. In apreferred embodiment, the lubricating fluid further includes TorqTrimIII, EP Mudlib, and DrillN-Slid. In a preferred embodiment, thelubricating fluid comprises TorqTrim III, EP Mudlib, and DrillN-Slid.

[1068] A tubular member has also been described that includes an annularmember having a wall thickness that varies less than about 8%, a hoopyield strength that varies less than about 10%, imperfections of lessthan about 8% of the wall thickness, no failure for radial expansions ofup to about 30%, and no necking of the walls of the annular member forradial expansions of up to about 25%.

[1069] A wellbore casing has also been described that includes one ormore tubular members. Each tubular member includes an annular memberhaving a wall thickness that varies less than about 8%, a hoop yieldstrength that varies less than about 10%, imperfections of less thanabout 8% of the wall thickness, no failure for radial expansions of upto about 30%, and no necking of the walls of the annular member forradial expansions of up to about 25%.

[1070] A method of forming a wellbore casing also has been describedthat includes placing a tubular member and an expansion cone in awellbore, and displacing the expansion cone relative to the tubularmember. The tubular member includes an annular member having a wallthickness that varies less than about 8%, a hoop yield strength thatvaries less than about 10%, imperfections of less than about 8% of thewall thickness, no failure for radial expansions of up to about 30%, andno necking of the walls of the annular member for radial expansions ofup to about 25%.

[1071] A method of selecting a group of tubular members for subsequentradial expansion also has been described that includes radiallyexpanding the ends of a representative sample of the group of tubularmembers, measuring the amount of necking of the walls of the radiallyexpanded ends of the tubular members, and if the radially expanded endsof the tubular members do not exhibit necking for radial expansions ofup to about 25%, then accepting the group of tubular members.

[1072] A method of selecting a group of tubular members also has beendescribed that includes radially expanding the ends of a representativesample of the group of tubular members until each of the tubular membersfail, if the radially expanded ends of the tubular members do not failfor radial expansions of up to about 30%, then accepting the group oftubular members.

[1073] A method of inserting a tubular member into a wellbore also hasbeen described that includes injecting a lubricating fluid into thewellbore, and inserting the tubular member into the wellbore. In apreferred embodiment, the thod of claim 774, wherein the lubricatingfluid comprises BARO-LUB GOLD-SEAL™ brand drilling mud lubricant.

[1074] Although illustrative embodiments of the invention have beenshown and described, a wide range of modification, changes andsubstitution is contemplated in the foregoing disclosure. In someinstances, some features of the present invention may be employedwithout a corresponding use of the other features. Accordingly, it isappropriate that the appended claims be construed broadly and in amanner consistent with the scope of the invention.

What is claimed is:
 1. An expansion member for radially expandingtubular members, comprising: a housing including a tapered portion andanother portion; one or more grooves formed in the outer surface of thetapered portion; and one or more axial flow passages formed in thehousing fluidicly coupled to the grooves.
 2. The expansion member forradially expanding tubular members of claim 1, wherein the groovescomprise circumferential grooves.
 3. The expansion member for radiallyexpanding tubular members of claim 1, wherein the grooves comprisespiral grooves.
 4. The expansion member for radially expanding tubularmembers of claim 1, wherein the grooves are concentrated around theaxial midpoint of the tapered portion of the housing.
 5. The expansionmember for radially expanding tubular members of claim 1, wherein theaxial flow passages comprise axial grooves formed within the outersurface of the housing.
 6. The expansion member for radially expandingtubular members of claim 5, wherein the axial grooves are spaced apartby at least about 3 inches in the circumferential direction.
 7. Theexpansion member for radially expanding tubular members of claim 5,wherein the axial grooves are formed within the outer surface of thetapered portion of the housing.
 8. The expansion member for radiallyexpanding tubular members of claim 5, wherein the axial grooves areformed within the other portion of the housing.
 9. The expansion memberfor radially expanding tubular members of claim 5, wherein the axialgrooves are formed within the conical and other portions of the housing.10. The expansion member for radially expanding tubular members of claim1, wherein the flow passages are positioned within the housing.
 11. Theexpansion member for radially expanding tubular members of claim 10,wherein the flow passages are positioned within the tapered portion ofthe housing.
 12. The expansion member for radially expanding tubularmembers of claim 10, wherein the flow passages are positioned within theconical and other portions of the housing.
 13. The expansion member forradially expanding tubular members of claim 10, wherein the flowpassages are positioned within the other portion of the housing.
 14. Theexpansion member for radially expanding tubular members of claim 12,wherein one or more of the flow passages include inserts havingrestricted flow passages.
 15. The expansion member for radiallyexpanding tubular members of claim 12, wherein one or more of the flowpassages include filters.
 16. The expansion member for radiallyexpanding tubular members of claim 1, wherein the cross sectional areaof the grooves is greater than the cross sectional area of the axialflow passages.
 17. The expansion member for radially expanding tubularmembers of claim 1, wherein the cross-sectional area of the groovesranges from about 2×10⁻⁴ in² to 5×10⁻² in².
 18. The expansion member forradially expanding tubular members of claim 1, wherein thecross-sectional area of the axial flow passages ranges from about 2×10⁻⁴in² to 5×10⁻² in².
 19. The expansion member for radially expandingtubular members of claim 1, wherein the angle of attack of the taperedportion of the housing ranges from about 10 to 30 degrees.
 20. Theexpansion member for radially expanding tubular members of claim 1,wherein the grooves are concentrated in a trailing edge portion of thetapered portion of the housing.
 21. The expansion member for radiallyexpanding tubular members of claim 1, wherein the angle of inclinationof the axial flow passages relative to the longitudinal axis of thehousing is greater than the angle of attack of the tapered portion ofthe housing.
 22. The expansion member for radially expanding tubularmembers of claim 1, wherein the grooves include: a flow channel having afirst radius of curvature; a first shoulder positioned on one side ofthe flow channel having a second radius of curvature; and a secondshoulder positioned on the other side of the flow channel having a thirdradius of curvature.
 23. The expansion member for radially expandingtubular members of claim 22, wherein the first, second and third radiiof curvature are substantially equal.
 24. The expansion member forradially expanding tubular members of claim 1, wherein the axial flowpassages include: a flow channel having a first radius of curvature; afirst shoulder positioned on one side of the flow channel having asecond radius of curvature; and a second shoulder positioned on theother side of the flow channel having a third radius of curvature. 25.The expansion member for radially expanding tubular members of claim 24,wherein the first, second and third radii of curvature are substantiallyequal.
 26. The expansion member for radially expanding tubular membersof claim 24, wherein the second radius of curvature is greater than thethird radius of curvature.
 27. The expansion member for radiallyexpanding tubular members of claim 1, further comprising: a tubularmember coupled to the outer surfaces of the conical and other portionsof the housing.
 28. The expansion member for radially expanding tubularmembers of claim 27, wherein the tubular member comprises: an annularmember, including the properties of: a wall thickness that varies lessthan about 8%; a hoop yield strength that varies less than about 10%;imperfections of less than about 8% of the wall thickness; no failurefor radial expansions of up to about 30%; and no necking of the walls ofthe annular member for radial expansions of up to about 25%.
 29. Theexpansion member for radially expanding tubular members of claim 27,wherein the tubular member comprises a wellbore casing.
 30. Theexpansion member for radially expanding tubular members of claim 27,wherein the tubular member comprises a pipeline.
 31. The expansionmember for radially expanding tubular members of claim 27, wherein thetubular member comprises a structural support.